Making Compressed Air smarter for your business
Compressed Air Management can give you more savings and productivity for your business
Manufacturing businesses in industries such as food and beverage, paper and printing, timber mills, and chemical and polymer production typically utilize compressed air systems.
Systems consisting of at least one or two screw compressors or a centrifugal compressor, can incur operational costs ranging from 10-30% of a site's electricity bill.
So it is imperative that you manage these machines well to keep them as a highly productive contributor to your bottom-line.
Did you know 90% of the electrical input is lost as heat, in leaks and to drive the motor? Just 10% remains as productive capacity for your business, as you can see in the diagram showing energy input and productive output below.
Breakdown of Compressor Input Energy. ~90% wasted in heat, mechanical losses, pressure losses and inappropriate air use.
Because compressed air systems are a critical component in many industrial processes, smart business leaders know they need their compressed air systems operating efficiently.
Without proper management, compressed air systems can become a substantial source of energy waste and a burden on the balance sheet.
On the flip side, when managed well, compressed air systems can return immediate cost savings.
Smart Compressed Air Management - Is Checking for Air Leaks an Easy Fix?
Sure, fixing air leaks can instantly improve energy consumption. And most specialists will begin by analysing air leaks in compressed air systems when trying to achieve savings. But, we know fixing air leaks is not the golden answer for smart compressed air energy management.
The success of success of fixing compressed air leaks to maximise electricity cost savings depends on different factors, such as:
The air quality,
How often and how well are the repairs completed
Root cause elimination
Compressor control system.
Besides checking for air leaks, you should be looking for other ways to achieve higher and more sustainable energy savings.
3 Burning Questions you should be asking your team about compressors:
Equipment/Operations: Are all compressors required?
Whilst 60% savings on lightly-loaded compressors sounds like a game-changer, it also raises the question: should your operations team reassess if the unit is really required?
Engineering Teams: Is the compressor built to the most efficient system design?
When a compressor is due for end-of-life replacement, how can engineering teams know the compressor sizing or how multiple compressors performance curves will interact to provide the most efficient system design?
Maintenance team: When is the time to act?
How will the maintenance team know when it is cost-effective to identify, prioritise and fix compressed air leaks? And how will they know if the leaks are successfully repaired?
And the million-dollar one for you:
How can you turn the expense turn into an investment in the future?
How can you mitigate the risk of engaging in projects that don't maximise the return on investment?
Smarter Compressed Air Management - A Management System
A systematic compressed air program will help your organisation save energy and money, improve productivity, and reduce downtime and maintenance costs.
. It can be valuable to optimise compressed air systems' efficiency, reliability, and safety.
A robust compressed air management plan should address elements such as:
Overall Efficiency
Air Quality (appropriate to the product and markets supplied),
Leak Management,
Heat Recovery and system integration,
Supply (Compressor House) and Demand (production floor) integration,
Maintenance scheduling,
Risk Management and Replacement Strategy,
Procurement Practices (system driven rather than supplier driven), and
Monitoring and reporting.
The benefits go beyond your bottom-line - Saving money, increasing productivity and improving reliability at a lower cost to the environment
Effective compressed air management leads to multiple benefits for businesses, including:
Energy cost savings: By implementing a compressed air management program, companies can identify and eliminate energy inefficiencies and waste, resulting in significant cost savings.
Increased productivity: A well-managed compressed air system enhances productivity by ensuring that the equipment operates efficiently and effectively, resulting in faster production times, fewer equipment failures, and less downtime.
Improved equipment reliability: Properly maintained compressed air systems can extend the lifespan of equipment by reducing wear and tear on components. This can result in fewer breakdowns and repairs, reducing maintenance costs and improving equipment reliability.
Environmental benefits: Compressed air systems can be a significant source of greenhouse gas emissions, specially if they are effectively managed. By implementing a compressed air management program, businesses can reduce their carbon footprint and show their commitment to sustainability.
Measuring the outcomes - Reporting energy improvements as dollar savings
You'll be required to measure energy savings. Measuring and tracking the performance of compressed air systems is an essential part of the process. In addition, it also helps to position you as a key contributor to your business.
In this stage, you should consider sub-meters to measure flow, pressure, and power. By installing meters on compressed air equipment, businesses can identify areas of excessive usage or pressure drops, indicating leaks, inefficient equipment, or incorrect pressure settings.
Financial Decision Makers and Operations Managers can then use the information to strategise the next steps.
Establishing Key Performance Indicators (KPIs)
You should compare the sub-metering data against a set of objective KPIs. It will allow you to manage costs long-term and ensure you can optimise the system as the plant evolves.
Leaders should customise KPIs to the individual needs of a site or business to track the performance of their compressed air system. Here are some KPIs for Compressed Air that are commonly used in the industry.
kWh/Unit of Production
What's next:
Be the one to suggest a solid compressed air metering system and active compressed air management in your business. In doing so, you help your organisation to achieve cost savings, improve equipment reliability, and reduce the environmental impact.
If you would like to learn more about how to turn energy efficiency into dollar savings, reach out to the friendly team at GECM by email or by phone at 03 9805 0788.