Tips to Lower Compressed Air Costs

Tips to Lower Compressed Air Costs

Compressed air is a necessity in many industrial applications, but it can be costly if you’re not careful. By investing some time and thought into your compressed air system, you can identify inefficiencies that, when fixed, will make compressed air an affordable solution by lowering Compressed Air costs.

Analyze air consumption

Typically, only half of generated compressed air is used for the intended process. The other half is depleted by artificial demand, inappropriate use and leaks. Artificial demand is created when there are extra margins on sizing compressed air systems in terms of flow or pressure requirement. It can account for about 10% to 15% of compressed air consumption, which translates into wasted money.

Inspect distribution

Inspecting your distribution means checking for leaks and assessing your pipe sizing. Both leaks and incorrectly sized pipes can result in unwanted pressure drops, causing your compressed air system to work harder and consume more energy. In some systems, leaks account for 20% to 30% of air consumption. Let’s take a look at some calculations and examples to understand the impact of distribution inefficiencies.

Pipe sizing and configuration

Pipe sizing may seem like a small factor, but it can have a big impact on pressure.  Another way to avoid air pressure drops associated with piping and configuration is to just say no to long hoses. Minimizing the use of hoses and frequently inspecting fittings can preserve line pressure without forcing the compressor to work harder than necessary.