A plant manager had been running the same manufacturing facility for nearly a decade, but compressed air had always remained a bit of a mystery. It was essential to the operation, yet notoriously expensive. He knew the compressors were energy hogs, and he was tired of watching electricity costs climb year after year. Determined to make a change, he started asking a simple but powerful question, “How do I make my compressed air system more efficient?”
His journey began in the compressor room, where a compressed air auditor introduced him to the first essential strategy, which he called Rule Number 1: Producing compressed air more efficiently. Together, they examined the existing screw compressors and quickly found a critical issue: the system lacked storage.
“You need at least five gallons of storage for every cfm of trim compressor capacity,” the auditor explained. The system was well below that target.
The plant manager followed the auditor’s recommendations: installing larger storage tanks, optimizing compressor control so multiple units didn’t compete with each other, and programming idle machines to shut off when not needed. He also carefully reduced the discharge pressure, only after confirming that downstream equipment could operate at the lower setting. Upgrades to cycling air dryers and low-pressure-drop filters further improved efficiency. Even replacing hot indoor intake air with cooler outside air gave the system a helpful boost.
With the compressor room now running more smoothly, attention turned to the second strategy, Rule Number 2: Stop wasting compressed air.
The team conducted a plant-wide leak audit using ultrasonic detectors and were shocked by the results, hundreds of dollars per week were being lost to unseen leaks. Repairs were made, shutoff valves were installed for idle equipment, and some air-powered devices were replaced with more efficient electric alternatives.
“Every 2 psi of pressure drop we eliminate saves money,” the auditor reminded the team as they improved piping layouts and upgraded filters, hoses, and connectors.
The final strategy was the most overlooked but offered surprising value, Rule Number 3: Using the heat from compression.
“Did you know about 90% of the energy that goes into an air compressor comes out as heat?” the auditor asked.
That insight sparked action. The team installed a heat recovery system to preheat water used in the plant’s cleaning processes. It cut natural gas usage and helped the facility move toward its sustainability goals.
Within months, the plant’s energy consumption dropped, system reliability improved, and compressed air problems became far less frequent. The plant manager’s only regret? Not taking action sooner.
Now, a sign hangs in the compressor room — simple but effective:
Compressed Air Optimization Rules:
- Produce air more efficiently,
- Waste less,
- Reuse the heat.
Those three strategies transformed this plant’s compressed air system from an overlooked utility into a well-tuned asset. Any facility, with a little attention and expert help, can do the same. Learn how by checking out the next Compressed Air Challenge training session on our calendar here: www.compressedairchallenge.org/calendar.
Filed Under: Air Compressors, Air Preparation, Components Oil Coolers, Compressed Air Technologies, Pneumatic Tips
