How to Reduce Your Air Compressor Costs: 7 Simple Tips
Many industrial processes require air compressors, but they typically consume about 10% of the energy used in developed countries, such as the UK, the United States, European Union, China, and other countries. Despite its many benefits, the associated costs can add up quickly. This makes efficient energy use and resource management essential for businesses. Therefore, it is essential to consider how businesses can preserve energy and efficiently use resources.
Reducing air compressor costs saves money and aligns with environmental goals by minimising energy consumption and reducing carbon footprints.
In this article, we’ll teach you 7 ways businesses can reduce air compressor costs without sacrificing quality or performance.
Table of Contents
1. Reduce Pressure Whenever Possible
For instance, operating your compressor at 10 bar when only 7 bar is required wastes energy and money. By lowering the pressure by just 1 bar, you can reduce energy consumption by approximately 7%.
For every bar that you lower the pressure of your compressed air system, your energy consumption can decrease by up to 7%, significantly reducing costs over time.
Using central controllers, such as Atlas Copco’s Optimizer 4.0, can help regulate and balance pressure across multiple compressors, ensuring efficiency while meeting demand.
2. Eliminate Air Leakages
A leaking air compressor does no good for business. Up to 30% of the energy in a compressed air system can be lost through leaks, translating directly into wasted costs.
Regularly checking your system for air leaks and fixing them as soon as possible should be a top priority.
Advanced leak detection systems, such as ultrasonic detectors, can identify leaks with high precision. Additionally, implementing continuous monitoring systems can provide real-time alerts for any leaks that develop.
Using ultrasonic detectors offers a reliable, modern way to identify leaks efficiently and quickly, saving time and reducing waste.
3. Optimize Ambient Temperature
You need a compressor room with the right conditions to get the most out of your equipment and reduce compressed air system costs. Reducing the ambient temperature by 5°C can lower energy consumption by up to 1.5%.
Keeping the air free from dust and moisture ensures clean, compressed air and reduces strain on aftercoolers, dryers, and filters.
For an additional boost in efficiency, intake air can be drawn from outside during cooler months, and waste heat from compression can be reused to control indoor temperature.
Using cooler ambient air from outside is a cost-effective way to enhance compressor efficiency, especially in colder climates.
4. Perform Regular Maintenance
Predictive maintenance tools, like SMARTLINK, allow for real-time monitoring and early identification of potential issues. Replacing filter elements on schedule minimises pressure drops and strain on the system, enhancing overall efficiency.
Predictive maintenance tools can identify potential issues before they occur, reducing downtime and ensuring consistent operational efficiency.
Businesses should take advantage of predictive and preventive maintenance tools and technology. These tools help to constantly keep air compressors working at their best, and reduce air compressor maintenance costs.
By keeping up with maintenance for your compressed air system, you can achieve maximum efficiency of the compressed air system. Changing filter elements at the correct time within the maintenance schedule, for example, reduces pressure drops, and alleviates additional strain on the compressor
5. Respect the Service Life of Your Machine
Newer models, like Atlas Copco’s GA VSD⁺ series, incorporate advanced variable speed drive (VSD) technology, reducing energy consumption by up to 60%. Although the initial investment may seem steep, these machines quickly pay for themselves through operational savings.
Modern compressor technologies, such as Atlas Copco’s GA VSD⁺ series, can reduce energy consumption by up to 60%, offering rapid returns on investment while lowering operating costs.
Significant advances have been made in compressor technology – like the GA VSDᣵ series, an evolution of variable speed drive (VSD) technology that can reduce energy consumption by up to 60%. And when the time comes for you to upgrade, investing in these more efficient machines typically pays for itself quickly, as operating expenses decrease.
6. Recover Heat
Compressing air generates a lot of heat. Businesses can either allow this heat to go to waste, or harness it for other purposes.
Heat recovery kits can repurpose up to 94% of the heat produced, significantly enhancing energy efficiency while reducing utility bills.
Heat recovery systems can reuse up to 94% of the energy lost during air compression. This heat can be redirected to warm water, support HVAC systems, or dry materials.
New technologies make it possible to recover and reuse most of the heat lost during compression. This heat can then be used to heat water, replace furnaces, or even dry things.
In many cases, major investments are not needed to make this happen. Simply connecting the compressor hot outlet to existing HVAC ducting during winter is enough to help heat up a facility.
Another technique is to use an energy recovery kit, which can heat up water for use in another location in the building.
7. Use Green Energy
As we know, compressed air systems consume a lot of energy, so business owners should consider going green. Installing clean and renewable energy sources like solar panels and wind turbines to power production processes will reduce energy costs in the long run.
Powering compressors with renewable energy sources, such as solar panels or wind turbines, reduce long-term energy costs while lowering your carbon footprint. Businesses can also benefit from tax incentives and government grants by investing in renewable energy technologies.
Transitioning to renewable energy for powering compressors lowers operating expenses and helps meet sustainability targets.
It’s widely known that investing in these technologies pays off both financially and environmentally. The long-term savings on energy costs are significant, and the reduction in CO2 output will help reduce your carbon footprint.
Advanced Modern Cost-Reduction Techniques
Anglian Compressors offers cutting-edge solutions that go beyond the basics. Our advanced control systems automatically adjust your compressor’s operation, ensuring it’s running only when needed and at peak efficiency.
Smart technologies like SMARTLINK provide real-time monitoring and control, ensuring energy savings and operational transparency.
How it works:
- Smart Sensors: These monitor your air demand in real-time, detecting even subtle changes.
- Intelligent Control: The system analyses the data and automatically adjusts the compressor’s output, avoiding wasteful energy consumption during low-demand periods.
The result? You’ll see significant reductions in your energy bills – often without sacrificing any productivity.
But that’s not all! We also offer remote monitoring and predictive maintenance tools. These technologies give you real-time insights into your compressor’s health, allowing us to:
- Spot Potential Issues: We can catch small problems before they become major breakdowns.
- Schedule Maintenance: We can proactively schedule maintenance during off-peak hours, minimising disruptions to your operations.
- Optimize Performance: We can fine-tune your system for maximum efficiency, ensuring you’re getting the most out of your investment.
Contact us today to learn more about how our advanced technologies can transform your air compression system.
Final Thoughts
These suggestions can help you meet strict regulations, reduce your carbon footprint, and decrease energy costs. Some tips, like fixing leaks, are low-cost and easy to implement, while others, like investing in VSD technology, offer long-term benefits.
Our team can help you implement advanced energy-saving measures tailored to your specific compressed air systems.
If you have questions on how to lower your energy bill and contribute to a cleaner environment, contact Anglian Compressors today.
Our team can recommend tailored solutions, including advanced monitoring systems and high-efficiency compressors, to help you operate sustainably while minimising costs.