Manufacturing facilities allocate about 40% of their total energy expenses to compressed air, making an efficient compressed air system essential for maintaining profitability. Unfortunately, not all systems function as efficiently as they could. We observe this frequently—compressors that are not properly sized, outdated technology, air leaks, pressure drops—the list goes on.
Rising energy costs are a common concern. The Energy Department has estimated that over 50% of industrial air compressors operate inefficiently, leading to 20% of energy waste each year. The positive news is that manufacturers in this study who focused on reducing energy costs managed to save over 15% annually, with a payback period of less than two years.
A comprehensive compressed air audit offers a detailed and thorough examination of your compressor system. This audit is conducted without interrupting your facility's operations, as it takes place while the equipment is operational. Typically, air audits employ data loggers to measure various parameters such as power (kW), pressure, flow, dew point, and temperatures, providing an in-depth analysis of the compressed air usage within the system. To collect the necessary information, data loggers are connected to the air compressor and across the compressed air network for a period of 7-14 days, allowing for the observation and recording of system dynamics during both the regular workweek and weekends.
The outcomes of these audits offer valuable insights into the real compressed air consumption over a specific timeframe, detect any anomalies in the compressed air system, and suggest methods to enhance the system's overall efficiency. Furthermore, each audit generally presents various options, such as air quality audits, maintenance evaluations, air leak detection and management, along with monitoring and control programs.
Compressed air audits can be conducted at different levels, including a walk-through assessment, system assessment, or a comprehensive system audit.