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Air compressors can be one of the most vital tools in an industrial workplace. They complete a variety of tasks, including painting, drilling, and sanding.
Compressors can also draw significant electricity &#; up to 30% of a site&#;s total electrical bill. This expenditure is why you need to take steps to maximize your compressor system&#;s efficiency.
Not sure how to save money with air compressors in your facility? Proper maintenance, routine care and a tailored preventative maintenance plan from C.H. Reed can be beneficial to you in saving money and time.
It takes about 8 horsepower of electrical energy to generate the electricity required for 1 horsepower of compressed air. This ratio is why it&#;s crucial to find and address compressed air saving opportunities within your facility.
The first step in reducing compressor costs is using the right compressor for the job. There are several different types, each of which offers various benefits.
If you need a new compressor, C.H. Reed has the solution you need for the job.
Leaks can result in a waste of 20-30% of your compressor output. Leaks are significant and must be addressed, especially when you consider the amount of money they could cost you. A 1/8-inch hole in a 100 psi system can cost more than $1,200 per year in energy costs. Repairing leaks can help reduce run time and maintenance and extend the life of your equipment.
You can sometimes hear leaks, but often they are not audible and you&#;ll help need to find them. Ultrasonic leak detectors are a common way of doing so. A planned maintenance check can provide a regular search for leaks in an air compressor system.
After fixing any existing leaks, you&#;ll want to prevent new ones from occurring. The inside of the piping system could tell you about the air moving through it and whether leaks are present. It should be clean and dry with no corrosion. Contamination in the pipe could indicate contamination in the air quality. Also keep an eye out for rust, which indicates moisture and can lead to leaks and air resistance within the pipes.
One crucial factor in keeping those pipes dry and clean is to use the proper filters and change them often. Do not attempt to change filters on an &#;as-needed basis.&#; Change filters according to a set schedule. Dirty filters inhibit the compressor&#;s ability to push air along the system and require more energy to do so. Replacing dirty filters is a simple and effective way to improve air compressor performance.
A dryer may or may not be necessary for your system. It depends on your usage. You&#;ll want to avoid drying more air than necessary, as this can be wasteful. Talk to one of our representatives for more information about drying solutions for your compressor system.
Selecting your filters is also important. You need to choose the type of filter that is necessary for your application, including filters meant for oil separation, high temperatures and particle filtration. Filters can also vary based on the technical specifications of your compressor.
Any point in your system that uses an air compressor could be exposed to unnecessary usage. For every increase of 2 psi, you also increase energy consumption by 1 percent. Cranking up the pressure or even purchasing a more powerful compressor to compensate for leaks or dips in pressure may sound like a good idea, but it will just waste more energy. This approach doesn&#;t address the fact that there is likely an underlying issue dampening the pressure, such as a clogged filter or leak. If you increase the pressure, you could be pushing more air out of the system.
Ensure that you are matching the pressure required to operate a machine to the pressure you are drawing from the compressor. A machine that pulls more air than it needs discharges that extra air after usage.
Your system&#;s overall design could be a factor in pressure reduction as well. A well-designed system should have a pressure loss of less than 10% of the compressor&#;s discharge pressure. After-coolers, separators, dryers and poor connections are some common culprits for this, especially when stacked since each one contributes to slower airflow. Our team at C.H. Reed can review your entire system and offer upgrades to improve efficiency and productivity.
Only run your compressed air system when it is needed. Unless your facility uses it 24/7, there are likely non-peak times when you can power down the air compressor.
Make sure the compressor isn&#;t used for tasks that can be completed with another tool &#; for instance, cooling may be accomplished just as easily with a fan or blower.
A sound control system can increase a compressor&#;s efficiency by working with both the compressor and the equipment it powers. Fine-tuned controls cue the compressor to release pressure, monitor flow and other, more complex parameters that will help it run better.
Some of the control types that a compressor may have include:
To get rid of all the water that compressors generate, you need an effective drain system. Automatic systems save time and labor. Manual and timed drains can waste precious air and could be less effective in a humid environment.
Zero-loss drains detect moisture and only open when it is present, meaning no compressed air is released. Also, make sure that you are cleaning the drain often.
Cool air is naturally more compressed than hot air and requires less energy to be fully compressed than warm air. Moving your compressor intake to a cooler area can improve performance. A 20&#; drop in temperature can lower operating costs by almost 3.8%.
The heat generated from an air compressor often goes unused. Up to 90% of this heat can be reused with a heat recovery unit. Typical uses include heating water for use in bathrooms or heating areas of the facility, such as work areas or warehouses, during cold weather.
If just 50% of heat loss is recovered to process water, at $0.50 per therm, you can save about $4,100 per year in natural gas costs.
Knowing many of the factors that influence compressed air savings, it may be time to reevaluate the design of your air compressor system.
C.H. Reed has team members with the expertise to redesign an inefficient system. They can provide suggestions and solutions to get your system running productively to reduce downtime and save costs.
Before optimizing your system, record your data. Research the energy consumption, airspeed and costs associated with your air compressor. Jot down the kW/h that you use, how much you pay for it and how long it runs. Then, determine the total cost.
You&#;ll also want to determine the energy demands of your facility. How much energy does your equipment require? Are you providing enough pressure for the highest demand or the minimum? Determine if you can limit energy use during high-demand times or turn the compressor down or off. Coordinate the information you&#;ve gathered about your operating habits with the information about electricity charge rates. You may be able to lower output during these times or consolidate usage to one compressor instead of three.
Compare the data from any proposed changes to the cost of your baseline. How do the costs line up? Once you&#;ve determined the configurations of usage that will reduce compressed air spending, you can review the layout of your site. This part of the process includes the locations of the equipment that will be using compressed air and the path that the air will have to take to get to them. Eliminating bends in pipes and even expanding pipe size are some things to consider.
Develop benchmarks and energy goals that you would like to reach. Keep a record of this information and update your findings after you&#;ve optimized your system.
An air compressor is a complex piece of equipment that needs constant monitoring to stay operating at peak efficiency.
The price of electricity for a leaky and clogged air compressor can make up a significant part of your utility budget. Maintenance costs can be minor when compared to replacing or fixing a broken machine. Even if your equipment still works fine, it may be costing you money in energy expenses. If you haven&#;t performed regular maintenance on your equipment, leaks, dirty filters and inefficient practices can all cause your electricity bill to skyrocket.
Reducing these can save not only money but also time. By preventing costly breakdowns and slow work practices due to decreased pressure, you can ensure that your facility is running on all cylinders. Regular maintenance can decrease downtime overall by increasing the efficiency and operational speed of your air compressor.
C. H. Reed has decades of compressed air industry experience throughout Pennsylvania, Maryland, Delaware, Virginia, West Virginia, Ohio and southern New York. Our preventative maintenance plans cover a wide range of air compressors and are specific to the type of machinery your facility has. We can even monitor your system remotely and keep an eye on its performance.
Depending on your equipment, maintenance may include but is not limited to checks for:
To set your workplace on a path of energy efficiency, air compressor preventative maintenance is a great way to bring in benefits for your equipment, your investments and the planet. It is one of the easiest ways to generate compressed air savings.
Contact us today to learn more about implementing preventative maintenance in your facility &#; and putting more money in your pocket.
How to Save the Most With Your Air Compressor System
You've landed on the right page if you want to reduce energy costs and increase your compressed air system's efficiency.
On average, manufacturing facilities waste roughly 30 percent of the air they produce. If you're not running an efficient compressed air system, you are wasting energy (and money) every day.
From eliminating pressure drops and leaks, upgrading outdated technology, and ensuring your compressor is the right type and size for the job, there's no shortage of ways you can save more over time.
This article will teach you how you can save thousands in the coming years by auditing your compressed air system and troubleshooting areas that can be improved.
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There's nothing more frustrating than discovering you've been given inaccurate information or weren't made aware of all your options. As compressor technology changes, it's important to do your own research to learn about new opportunities to improve your system and see massive returns and energy savings.
You may not have known about these options when you installed your system, but that's okay. In a past study, the U.S. Department of Energy determined that only about 9% of manufactures they interviewed said that the efficiency of their compressor system was a primary business objective, and out of the total number interviewed, the awareness that they could make improvements was substantially low.
The good news is, over 58% of those manufacturers wanted to increase their efficiency once they knew they had options to do so. Today's economy requires manufacturers to eliminate as much wasted costs and energy as they can, so it's never too soon to start making changes that will save you money in the long run.
You've probably heard that investing today will pay off tomorrow, and for air compressors, this is true.
For example, rotary screw compressors are more expensive up-front, but it would take 10 years for the energy cost to equal the cost of the compressor. With some piston compressors, that can happen as soon as a single year.
There are a hundred considerations when it comes to efficiency and reducing costs. To keep things simple, below we take a quick look at the most important ones.
First, it's important to understand that your air compressor should never be overworked. In fact, you should size your air compressor so it can handle at least 25% more than your maximum CFM and PSI (load) requirements when running. That way, your compressor won't be running at full capacity all the time and burn out the motor quickly while trying to keep up with your air demands.
The strongest workhorses in the industry are rotary screw air compressors, which satisfy both energy savings goals and heavy air-delivery demands. Investing in a rotary screw compressor not only makes your system more efficient, but it will save you money, run quieter, and run longer than traditional piston-type air compressors.
Rotary screw compressors have a 100% duty cycle that continually provides specific pressure and flow 100% of the time and can run continuously without shutting down or overheating. And, because the internal screws don't touch, there's less friction and maintenance, and fewer replacements that you need to worry about.
On a similar note, you should size your compressor while considering company growth, future expansion, and increased air demands so you won't have to purchase a larger compressor every time your business grows.
You'll regret the decision to buy a smaller compressor for less if you end up needing a larger one soon after. The right choice is to invest in future growth and purchase the compressor you will need the first time.
Your compressor should never have to work harder than the job requires, and should only be running at the speed it needs to get the job done. That's why Variable Speed Drive Technology (VSD) was created: to maximize efficiency by delivering the right amount of compressed air at the right pressure&#;with the right amount of effort.
Unlike regular compressors, VSD compressors don't operate at full-bore all the time; their compressing speeds continually change Revolutions Per Minute (RPM) to match the CFM/PSI demands the load requires. It's similar to how a governor controls the engine of a semi-truck.
Recent innovations in air compressor technology have brought VSD options to 2-stage compressors as well, giving industries the ability to switch from single-phase to 3-phase power, satisfying the requirements of complex jobs without needing to use multiple compressors. Compressors that use this new technology are in high demand because:
They can be customized and programmed to perform as desired
The technology enables larger units to be used in home garages & small shops
They allow the user to operate in single or 3-phase power with voltages ranging from 208-230V
Now that you've thought through the biggest considerations, it's important to remember the rest of your air compressor system needs a closer look, too.
While the compressor is the heart of your system, it's not enough to simply replace it if it gets old. To maximize your savings and extend the life of your system, you need to check and monitor all the parts that work together in harmony to prevent wasted energy or unnecessary strain on the components.
For example, examining your air delivery system can point to any spots or joints where you are losing pressure or leaking air, causing your compressor to work harder to sustain your PSI/CFM requirements. That means wasted energy, money, and air.
Treating compressed air is critical, especially if your company spends thousands on an air compressor. Protect your investment by ensuring that the air that passes through the lines is clean and dry. In fact, almost nothing will damage your system or air tools more than dirty, unfiltered air.
Choosing (and replacing) the right air filter is critical for removing impurities in the air like aerosol contamination, small particulates, or oil that can damage your system and waste energy over time. It's a lot like replacing your car's air filter; if you ignore it too long, it stops working properly. Your gas mileage (efficiency) will decrease, and your engine will work harder gasping for the air it needs to run properly.
Compressing air quickly creates a lot of heat and condensation. Defend your system's longevity by investing in air dryers that will cool and remove the moisture in the compressed air that would otherwise damage the tank, lines, and other components of your system over time. If you're using the wrong type of air dryer, you're wasting a lot of money by overworking the dryer to fulfill a purpose it wasn't built for.
A refrigerated air dryer will work perfectly in a compressor system that has another means of cooling air to help it along. If it doesn't, a regular refrigerated air dryer will work longer and twice as hard to cool high-temperature air&#;resulting in wasted energy, shorter dryer lifespan, and money out of the bottom line. There are high-temperature air dryers designed for this purpose and run efficiently at those heavy workloads.
Now that you know more about some things you can do to save big money in your facility over time, the next step is to take a deeper look into the system you're currently using and see what the numbers actually say&#;an air compressor system audit.
You should never make a business decision without crunching the data first. If your compressed air system is a critical part of your business, using a data-logging device will record the activity of your compressor system over time, which will show you a highly-accurate load profile for your compressed air demands and point to any irregularities, losses, or opportunities for improvement.
Even if you're not running a large manufacturing facility, you can still benefit greatly by auditing your current compressor setup. Consider finding a field specialist who will monitor and record a small chunk of that data, and perhaps recommend where improvements can be made.
As soon as you determine the parts of your system that can be improved, the sooner you can start saving valuable energy dollars that will bolster your bottom line.
NEXT: Rotary Screw Compressor Buyer's Guide
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Main Guide | Commercial Buyer's Guide | Reduce Energy Costs | How to Audit Your System | VSD Technology | Air Treatment Systems
By Melissa C.
Air Compressor Expert
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