Compressed air is essential for many businesses, and different types of compressors can be found in thousands of companies, big and small, across the country. The UK government estimates that compressors account for approximately 10% of industrial energy usage, equating to about 8.8 TWh annually. This is enough to power around three million homes.
That figure is an estimate (of course) and you might find your compressor accounts for more or less than 10% of your energy bills. However much you are spending, there’s probably room for improvement and there are excellent reasons to make your compressor as efficient as possible.
- An efficient compressor is a low cost compressor. The better it is at compressing air, the less it will cost you.
- Improving efficiency helps the environment. You use less energy with the compressor, as well as improving the processes it powers, reducing the environmental impact.
- Your compressor will thank you. Those small inefficiencies often result from problems that just get worse. Keeping your compressor efficient will also keep it running well for longer, saving you even more in the long run.
What does air compressor efficiency mean?
Air compressor efficiency is about maximising output while minimising energy consumption and costs. A well-optimised compressor system ensures your compressed air generation meets demand efficiently, reducing the cost of compressed air and extending equipment life.
Key inefficiencies include:
- Heat Waste – compression generates hot air; recovering it through an energy recovery system can cut energy use.
- Pressure Drops – poor compressed air installation and clogged air filters force the compressor to work harder.
- Leaks – even small leaks waste substantial energy. Ultrasonic detection helps pinpoint them.
- Incorrect Sizing – an inefficient compressor wastes energy, while undersized units struggle to maintain free air delivery.
- Noisy Operation – unusual noise often signals inefficiencies in compressor speed (RPM) or mechanical efficiency.
Boosting volumetric efficiency lowers operating costs, improves compressor output, and ensures higher efficiency. Whether through better system design, leak detection, or energy recovery, optimising your compressed air system delivers substantial energy savings over time.
Why is regular maintenance and inspection so important?
Routine maintenance is key to keeping your compressed air system energy efficient, reducing electrical energy costs, and preventing breakdowns. Over time, leaks, clogged air dryers, and worn components increase compressor energy consumption and impact performance.
Key Benefits of Maintenance:
- Prevent Leaks and Pressure Drops – even small leaks cause a drop in system pressure, forcing your compressor control system to work harder.
- Optimise Performance – ensures compressor output, intake air, and air drawn remain efficient.
- Protect Air Quality – clean air dryers and filters maintain dry air for air tools and production.
- Reduce Energy Waste – preserves isentropic efficiencies, lowering energy consumed.
- Extend Equipment Life – reduces wear on reciprocating compressors, rotary screw compressors, and centrifugal compressors.
How Often Should You Inspect Your Compressor?
✔ Daily/Weekly – check for leaks, air heat, and pressure fluctuations.
✔ Monthly – clean air filters, track air consumption, and monitor compressor calculations.
✔ Quarterly/Annually – conduct full efficiency-based energy audits and replace worn parts.
Preventative Maintenance Pays Off
A well-maintained compressor package improves reliability, reduces total compressed air costs, and ensures that users benefit from substantial energy savings. Investing in maintenance helps you use your energy savings effectively while ensuring long-term efficiency.
How do you maximise energy efficiency?
The good news is that almost every compressor can be more efficient, and taking care of the normal wear and tear a system experiences will pay dividends. Although, sometimes, a lot more is needed to maximise efficiency. Here are some ways to ensure your compressed air isn’t costing you more than it should:
Do you have the right compressor?
Choosing the right compressor is the first step to optimising energy efficiency. Even if your current unit is doing the job, it may not be the most efficient air compressor system for your needs today.
Variable speed compressors are ideal for businesses with fluctuating demands, helping to lower energy consumption by adjusting motor speed to match the required compressed air output. But it’s not just about motor speed – changes in your operations might mean your older compressed air system is now oversized or undersized. An oversized unit often runs inefficiently at partial load, while an undersized one can suffer from increased energy consumption and wear.
Ambient conditions matter too. Compressors perform best when drawing in cooler intake air. Improving air equipment positioning and filtration can also further save energy across the system. Reviewing the pressure settings of the compressor is equally important; reducing compressor pressure bands without affecting your applications can significantly improve system efficiency.
If you’re unsure whether your compressor is still the right fit, reviewing your air compressor energy efficiency could highlight hidden energy losses. We’ve helped many businesses upgrade to more efficient parts and equipment, recovering costs quickly through better performance and reduced compressor maintenance.
Use energy management systems
Sometimes, it’s just a case of turning on a compressor and letting it work, but demands shift during the day for most operators. Energy management systems (EMS) provide real-time tracking of key indicators such as flow, pressure, and power consumption. These insights allow you to fine-tune your system for maximum efficiency.
The data is provided in a convenient remote dashboard which allows you to check in on your compressor at any time of day and night. Believe us, it can be surprisingly addictive to track the data and tweak your energy efficiency.
However, that data also helps you understand your system, and many have found that it doesn’t just help them keep their compressor working optimally, but the usage can signpost them to potential workflow improvements elsewhere in their operations.
Is your system design letting you down?
It’s important to consider not just the air compressor, but the entire system it supports. Compressed air is a superb way to transmit power, but it works best when the piping is optimalt.
A well-designed system will avoid unnecessary bends and minimise length. Often, changes to operations will see piping systems adapted, and over time, these adaptations will hamper the air compressor’s efficiency.
It’s also important to have regular leak testing. If you have an EMS you might see a pressure drop that indicates an air leak, but these are frequently inaudible, especially in a working environment. Using ultrasonic equipment enables you, or the servicing engineer, to quickly find leaks.
Ultrasonic equipment can pinpoint leaks effectively, even in noisy environments.
Use heat recovery
Heat recovery systems capture and reuse heat generated during air compression. This energy can be repurposed for production processes, space heating, or water heating, reducing overall energy costs. By redirecting waste heat, facilities can achieve savings of up to 20% of their energy input.
Audit your compressed air system regularly
Regular audits are crucial for keeping your air compressor system running efficiently and controlling total energy costs in industrial operations. Over time, even small leaks, outdated piping, and unnoticed changes in pressure settings can cause significant energy losses.
An audit examines the entire compressed air network, checking compressor pressure bands, tracking flow and pressure, inspecting air equipment, and reviewing air dryers and filters. Even small changes, such as reducing pressure without affecting applications, can lower energy consumption and improve system efficiency.
Audits also highlight sources of energy waste, such as artificial demand and waste heat from air compressors that could be recovered and reused. Reducing these inefficiencies not only saves energy but also cuts total energy consumption and CO₂ emissions across your site.
Building benchmarks through regular audits gives you a clear view of your system’s health over time. Catching issues early helps maintain efficient operation, extend the lifespan of your equipment, and avoid costs due to wasted energy.
How to start maximising your air compressor efficiency
Your needs will determine the best approach. If you use a lot of compressed air, you might find investing in your compressor efficiency, even with dedicated staff time, worthwhile. Even if you are a light user, you will still benefit from ensuring your compressor is working optimally.
Start at ground level
Engage the people closest to the equipment. Ensure that any changes – such as unusual noises or reduced tool performance – are reported. These signs often indicate emerging inefficiencies.
Monitor the whole system
Think beyond the compressor. Changes in energy bills or tool performance could indicate broader system inefficiencies. EMS tools provide comprehensive monitoring, but even manual checks can uncover issues. A change in your energy bill, or variations in the outputs of people using pneumatic tools, might be the result of a drop in compressor efficiency.
Take a strategic view
Energy audits provide an opportunity to evaluate the bigger picture. Look for inefficiencies introduced by system changes, such as new piping configurations. Consider whether your compressor still meets your needs or if upgrading to a modern system would be more cost effective.
Get expert help
There’s a lot you can do to improve and maintain your air compressor efficiency, but it’s always worth getting expert help. We’ve been designing and installing, and servicing and maintaining compressed air systems in the region for over eighty years.
Whether you are looking for an entirely new system, want a full audit of an existing system, or just want someone to take care of the routine maintenance, we can help.
While there’s much you can do in-house, engaging experts ensures your system operates at peak efficiency. Professionals can provide detailed audits, recommend upgrades, and offer proactive maintenance.
At J LL Leach, we have over 80 years of experience designing, installing, and maintaining compressed air systems. Our fully stocked depots across the region ensure rapid support.
FAQ
How can I make my air compressor installation more energy-efficient?
To make your air compressor installation more energy-efficient, focus on regular maintenance, fixing air leaks, and ensuring the compressor is properly sized for your needs. A variable speed drive (VSD) compressor can adjust the air supply based on demand, reducing energy waste. You can also recover waste heat from compressed air production and monitor the pressure settings to ensure optimal performance.
What is the impact of choosing the wrong size air compressor?
Choosing the wrong size air compressor can lead to inefficiencies in your compressed air system. An oversized compressor may result in excessive energy consumption, while an undersized one will struggle to meet the demand, leading to increased wear and higher operational costs. Selecting the correct air compressor to match your specific compressed air volume requirements is important.
How do I achieve compressed air energy savings in an industrial air system?
To achieve energy savings in an industrial compressed air system, consider conducting a compressed air audit to identify inefficiencies. Fixing air leaks, using compressor controllers, and maintaining the correct target air pressure can significantly reduce energy consumption. Additionally, integrating energy-efficient compressors and optimising the use of cooler air, which requires less energy, will further enhance overall efficiency.
How can I improve my compressor’s efficiency and reduce the energy required?
Ensuring your existing compressor operates efficiently starts with regular maintenance, leak detection, and optimising the compression stage. Upgrading to an efficiency-based compressor control system or investing in an Atlas Copco compressor can enhance performance. Additionally, recovering waste heat and monitoring compressed air demand can help reduce operating costs.
What are the best ways to reduce compressed air demand in my system?
Reducing compressed air demand starts with eliminating leaks, optimising piping, and maintaining air and refrigerant drying systems to ensure high air quality. A central compressor setup can help balance output efficiently while selecting the right compressor type based on usage patterns ensures that energy is put to good use instead of being wasted.
Why is choosing the right compressor type important for long-term savings?
Different compressor types – such as rotary screw, reciprocating, or centrifugal compressors – offer varying benefits depending on application and demand. Working with reputable compressor manufacturers like Atlas Copco ensures you select the best unit for your needs. The right compressor improves air quality, minimises waste within the compressor, and significantly reduces the energy and money spent on operation.
How can I make my compressor installation more energy efficient?
Improving compressor performance starts by ensuring that the compressor matches the air you need and is not producing more compressed air than necessary. Best practice tips can help reduce energy losses, such as adjusting the pressure band without affecting the supported applications. Installing an energy recovery system and maintaining equipment properly are also crucial steps to lower energy consumption and CO₂ emissions.
Why does reducing system pressure help improve energy efficiency?
Compressed air accounts for a significant source of energy use in many businesses. Reducing the pressure band, without affecting the applications, cuts the amount of energy needed to overcome system resistance. A compressor should be adjusted to deliver the required compressed air at the lowest effective pressure, which improves energy efficiency and reduces energy costs for industrial manufacturers.