Compressed Air Systems are very widely used in almost all manufacturing industries and are usually the Single Highest Source of Energy Consumption in a Plant. Through Out the Compressor’s Life Time More than 76 % of the Costs are spent towards its Energy with the Capital and Maintenance Cost only at 12 % Each.

Further more Compressed Air Systems consume High Energy due to various losses happening during its Generation, Distribution and Consumption. Given below is a simple chart explaining common losses happening across the Compressed Air System.

A Compressor Loses Almost 50% of its Input Electrical Energy in the Form of Heat. Leaks are another Common Form of Losses in Industrial Compressed Air Systems Usually Accounting for Upto 20 % of the Compressed Air System Capacity. Unregulated End Points increase the Air Consumption and are hence rightly termed as Artificial Demand. Artificial Demands Exists between 5 – 10 % in any given Plant. Losses resulting due to Usage of Compressed Air in applications which can operate with alternate sources of Energy are termed as In-Appropriate Uses and they usually range between 5 – 10 % of the Overall Energy Loss in the System.

Common Pain Points in Operating a Compressed Air System

• High Energy Costs
• Re-occurrence Of Leakages
• Poor Air Quality
• Higher Cost Of Ownership
• Production Interruption
• Frequent Break-down
• High Maintenance Costs

Compressed Air Systems Normally Experience

• Excessive Energy Utilization
• Non Productive Efforts
• Asset Depreciations
• High & Repeated Efforts
• Confusion – Where to Start?