How to Make Your Air Compressor More Efficient
Air compressors are a critical utility for many UK businesses, powering everything from manufacturing processes to automotive repairs. But inefficient air compressors can significantly increase energy costs and impact productivity. Whether it is for manufacturing plants, food production or the automotive industry, industrial air compressors are an excellent tool power source. Still, there is always more that can be done to ensure maximum air compressor efficiency and reduce running costs.
An energy-efficient air compressor will deliver lower energy bills, boost productivity, reduce the need for maintenance, and be more environmentally friendly overall, helping your business contribute to Net Zero targets.
There are various types of compressors used by companies in factories and small commercial units, each with its own efficiency rating. Rotary screw air compressors and scroll air compressors are generally the most efficient types. However, rotary vane and piston air compressors have advantages for certain tasks.
Variable speed drive air compressors are gaining in popularity, too, thanks to their ability to adjust the motor speed and output based on fluctuating air demand, potentially reducing energy consumption by up to 50% compared to fixed-speed models.
Whatever industrial air compressor you use, there are always ways to make it run more efficiently. We will explore the to methods for improving the efficiency of your air compressor.
How to Make Your Air Compressor More Efficient
Frequent maintenance
Older air compressors require regular preventive maintenance to keep them functioning at their best, like any other equipment. An air compressor maintenance checks helps identify minor issues before they escalate into major problems, which are more costly to fix and cause unexpected downtime.
During a maintenance check, a qualified technician can test the seals, clean out or replace air intake filters, check the belts, add lubrication if needs be, and detect leaks. These things together add up to a finely tuned compressed air system capable of performing much more efficiently.
For Atlas Copco users, integrating remote monitoring technology like SMARTLINK can take this a step further. Remote monitoring technologies can significantly enhance maintenance practices by providing real-time performance data and alerting you to potential issues before they become critical. This allows you to track performance in real-time and spot service needs before they become critical.
How regularly your air compressor needs maintenance depends on factors such as the size of the air system, how often it is used, what pressures it is operating at, and how old the air compressor is. Basic inspections can be done daily or weekly, such as moisture drainage and listening for unusual noises, but, for most machines, we recommend a health checkup every six months.
Check the pressure
It is a good idea to pay attention to the pressure settings of the compressor as it is possible to reduce the pressure and still benefit from the same performance. Many air systems have the pressure set too high, creating “artificial demand” which has a knock-on impact on the cost of energy it uses.
As a general rule, you save approximately 7% in energy for every 1 bar of pressure you reduce in the air system. So, adjust pressure settings based on the task at hand and reduce pressure during periods of low demand to minimise energy waste, following these simple steps.
Pressure drops caused by clogged filters or poor piping also reduce productivity for tools using compressed air, as they need the necessary pressure to work efficiently. Pressure fluctuations, whether too high or too low, can damage the air compressor and cause failure of certain parts.
Look for air leaks
One of the major causes of energy wastage in an air compressor is a leak in the system. An air leak can reduce the output by a massive 30%, and there is an associated jump in energy costs. In fact, a single 3mm leak could cost your business over £2,800 per year. A constant decrease in pressure is a good indicator of a leak in the system, and several reasons may cause it.
A damaged hose is one of the main culprits of an air leak, especially when used in an environment with lots of vibrations or movement. The connectors that fit hoses can also be at fault and need tightening.
Couplings, seals, gaskets, and valves are other potential parts that could be responsible for a leak. So, it is best to have frequent air compressor maintenance utilising ultrasonic leak detection to resolve any of these issues and restore efficiency quickly.
Upgrade your system
Upgrading to a newer air compressor can offer significant energy savings thanks to advancements in motor technology, control systems, and overall design. News of these improvements are always welcome. A more efficient motor, such as the IE5 Super Premium Efficiency motors found in the Atlas Copco VSD+ range, can be installed to cut energy consumption, which is helpful when you need a steady flow of air for specific machinery and tools.
For example, the filter air system and pressure regulators can be upgraded and swapped for new models with proven energy-savings benefits. Energy consumption can be reduced drastically by using a VSD air compressor, which alters the output according to compressed air demand. If you are upgrading, take advantage of the UK government’s “Full Expensing” capital allowance to write off the cost of new, more efficient plant machinery.
Upgrading your air compressor does not have to be expensive. Sometimes, small improvements can make a big difference. New tubing and valves, for example, do not cost the earth but can help to keep your air system performing at its optimal capacity.
Optimise the system layout
If you already have a large air compressor setup in an industrial or commercial unit, consider optimising the piping layout. Bottlenecks, sharp bends and rough piping reduce efficiency, and you can even consider changing the diameter of pipes to get the most out of your air compressor.
Switching from galvanised steel to smooth-bore aluminium piping, such as AIRnet, can significantly reduce friction and pressure drops, ensuring your air supply reaches the tools with minimal energy loss.
Installing central controllers capable of detecting flow and pressure settings and altering the output is another way to enhance efficiency. Real-time data can be analysed by a smart system or an engineer working remotely and monitoring air system efficiency.
The design and installation of a new air system can have a large initial outlay but, in the long run, your business will save money every time the equipment is used.
Recover waste heat
One often overlooked method to save energy is heat recovery. Approximately 94% of the electrical energy used by an air compressor is converted into heat. Without energy recovery, this heat is simply vented into the atmosphere.
By installing an energy efficiency recovery unit, you can capture this waste heat and use it to warm your factory, heat water for industrial processes, or pre-heat boiler feed water. This can significantly offset your facility’s operations heating costs and lower your carbon footprint.
Conclusion
If you are experiencing air compressor inefficiency, it is best to reach out to a professional air compressor service such as Search Air to diagnose the main problems. A maintenance checkup, or better yet, a full air compressor audit using data logging, is the best way to determine your air system’s overall health, identify hidden inefficiencies, and ensure there are no leaks or parts that need replacing.
If your air system is still not performing as efficiently as you would like, you can discuss further options like air system upgrades, air system optimisation, and new parts with a qualified engineer.
FAQs
How can I reduce the energy cost of my air compressor?
To reduce energy costs, focus on fixing air leaks, lowering air system pressure by 1 bar (saving ~7% energy), and switching to a Variable Speed Drive compressor if your demand fluctuates. Regular maintenance is also key.
What is the most efficient air compressor for industrial use?
Rotary screw compressors with Variable Speed Drive technology, such as the Atlas Copco VSD+ series, are generally the most efficient for industrial use as they adapt motor speed to match air demand.
Is a VSD compressor worth the investment?
Yes, for most businesses with varying air demand, a VSD compressor is worth the investment. It can reduce energy consumption by up to 50% compared to a fixed-speed model, offering a rapid return on investment.
What is the impact of ambient temperature on air compressor efficiency?
Ambient temperature plays a crucial role in air compressor efficiency. Higher intake temperatures mean the air is less dense, requiring the compressor to work harder to achieve the desired pressure. This increased workload translates directly into higher energy consumption and reduced efficiency. Proper ventilation and cooling systems can help mitigate this issue, especially in enclosed industrial settings.
Why is correct air compressor sizing important?
Correct air compressor sizing is paramount for optimal efficiency. An undersized compressor will run constantly, struggling to meet demand and leading to premature wear and increased energy consumption. Conversely, an oversized compressor will cycle on and off frequently, which is also inefficient. Proper sizing ensures the compressor operates within its optimal performance range, minimising energy waste and maximising lifespan.
How does air management improve air compressor efficiency?
Effective air management is crucial for maintaining air compressor efficiency. This includes optimising the system layout to minimise pressure drops, using appropriate piping materials to reduce friction, and implementing central controllers to monitor and adjust output based on real-time demand. Proper air management ensures that compressed air reaches its destination with minimal energy loss.
How often should I perform air compressor maintenance for optimal efficiency?
The frequency of air compressor maintenance depends on several factors, including the size of the system, usage frequency, operating pressure, and age. While basic inspections like moisture drainage and noise checks can be done daily or weekly, a comprehensive health checkup by a qualified technician is recommended every six months for most machines. Regular maintenance helps identify and address minor issues before they escalate into major problems, ensuring optimal efficiency and preventing costly downtime.
What is the role of air audits in optimising efficiency?
Air audits play a vital role in optimising air compressor efficiency by uncovering hidden inefficiencies within the system. A professional air audit, such as Search Air’s AIRScan service, uses data logging and ultrasonic leak detection to identify leaks, pressure drops, and other areas of energy waste. By addressing these issues, businesses can significantly reduce their energy consumption and improve the overall performance of their compressed air system.
How can I calculate my current air compressor efficiency?
While a precise calculation requires specialised equipment, you can estimate your air compressor’s efficiency by comparing its energy consumption to its output. Start by tracking the compressor’s power usage (kW) over a specific period and measuring the amount of compressed air delivered (CFM). Then, compare these figures to the manufacturer’s specifications to identify any significant deviations. A professional air audit can provide a more accurate assessment and identify specific areas for improvement.
What government incentives and rebates are available for energy-efficient compressors in the UK?
The UK government offers various incentives and rebates to encourage businesses to invest in energy-efficient equipment, including air compressors. These incentives may include tax breaks, grants, and subsidies for upgrading to newer, more efficient models. For example, the “Full Expensing” capital allowance allows businesses to write off the cost of new, more efficient plant machinery. Contact Search Air to learn about the latest available incentives and how they can help you save money on your air compressor upgrade.
What is the future of air compressor technology?
The future of air compressor technology is focused on increased energy efficiency and sustainability. Emerging trends include advanced motor designs, variable speed drives with wider operating ranges, and sophisticated control systems that optimize performance based on real-time data. Additionally, there is a growing emphasis on waste heat recovery and the use of environmentally friendly refrigerants. These advancements promise to deliver significant energy savings and reduce the environmental impact of compressed air systems.
Contact Search Air today for a free consultation and discover how we can help you optimise your compressed air system for maximum efficiency and cost savings. We serve businesses throughout Yorkshire, the East Midlands, and across the UK.