Stop paying for air you never use.
Most compressed air systems are wasting 20-30% of their energy output. Air leaks, unloaded running, excess pressure and no heat recovery are common, fixable problems.
Compressed air accounts for 10 to 30% of industrial electricity use in a typical manufacturing facility. Figures are J&J’s own, from their website.
Measure the system properly.
A week of data logging will typically reveal more about your system’s real performance than years of operator observation. We use data logging and ultrasonic detection equipment.
You receive a written report with findings prioritised by estimated energy waste, recommended actions and a projected saving for each. There is no obligation to use us for the remedial work.
What we look at
- Air leaks, located, mapped and costed individually
- Actual consumption versus compressor output
- Whether working pressure is set higher than needed
- Compressor utilisation and part-load running
- Periods of high unloaded running
- Pressure drop across distribution, filters and treatment
Where the savings come from
Pressure optimisation
Every 1 bar reduction in system pressure reduces compressor energy consumption by approximately 7%. A secondary low-pressure circuit may let the main system run lower.
VSD compressors
Motor speed follows demand. Typically pays back within two to four years through energy savings alone, with reduced wear and longer service intervals.
Heat recovery
Retrofittable to most rotary screw compressors. Typically between one and three years payback, offsetting gas or electric heating costs.
Flow monitoring
Continuous visibility to spot problems early, and consumption data for ISO 50001 energy management or carbon reporting.
We are not trying to sell you a new compressor. However, sometimes that is the right answer, and we will say so if it is.
Where to start
Tell us your compressor make, model and approximate running hours per day, and your electricity rate per kWh. We can give you a rough indication of whether there is worthwhile saving to be made.
Energy FAQ
Why are leaks so costly?
In systems with no active leak detection programme, 20-30% of output can be lost, and most leaks are inaudible without specialist equipment.
What happens to the heat from a compressor?
Up to 94% of the electrical energy input is converted to heat. On most sites it is vented to atmosphere. Heat recovery redirects it for space heating, process water heating or other thermal uses.
Find out where your compressed air energy is going.
A written audit report, prioritised by estimated waste.