A Guide to Air Compressor Monitoring Systems
With the UK’s high and rising energy prices, finding innovative ways to reduce your consumption is now more critical than ever. In competitive industries such as automotive and manufacturing, maintaining quality is crucial. Therefore, relying on industrial air compressors and other high-energy equipment becomes essential.
Fortunately, the latest monitoring systems can significantly reduce the energy usage of your air compressor unit, which might account for a significant portion of your overall consumption. And they can do much more than just shave a handsome sum off your running costs.
Our range of air compressor monitoring systems is equipped with high-tech features like advanced control systems, remote monitoring and automation, giving you more flexibility over the management of your operation while increasing workplace efficiency. They can also help ensure you remain compliant with the UK’s ever-evolving regulations like ESOS Phase 4 and improve your workplace air quality.
At Search Air, we work with industry-leading manufacturers like Atlas Copco to provide state-of-the-art compressed air equipment for the manufacturing, automotive, pharmaceutical, oil and gas industries, and more. We have been a Premier Distributor for Atlas Copco since 2001, so you can feel confident that we can tailor a bespoke solution for your needs. Call us to find out how we can bring your business up to speed.
What is a Compressed Air Monitoring System?
A modern air compressor monitoring system gives you full visibility over your entire compressed air setup’s system performance, efficiency, and condition. It tracks key parameters like air pressure, temperature, dew point, flow rates, vibration, and energy use, providing real-time monitoring and valuable trend analysis.
Advanced monitoring tools offer more than just fault detection – they support predictive maintenance, helping to improve system reliability and avoid costly downtime. Some solutions even monitor environmental factors such as humidity to fine-tune your air supply performance. By utilising data from your compressed air system, you can identify issues like pressure drops or leaks immediately.
By choosing the right air compressor monitoring system, you can optimise your compressed air energy use, extend equipment lifespan, and ensure your compressed air system operates as efficiently and reliably as possible.
Different Types of Air Compressor Monitoring Systems
Because we know there is not a one-size-fits-all solution for the industries we serve, we can design monitoring systems using the most advanced Atlas Copco equipment to meet your unique needs, whether you need to monitor a single compressor in a workshop or a network of them across multiple sites. Broadly, our solutions fall into the following categories.
Local Monitoring Systems
The most basic solutions focus primarily on service warnings, often utilising integrated controllers like the Atlas Copco Elektronikon®. This is ideal for small businesses like workshops and garages. These systems provide flexible options for on-site control but may lack the remote accessibility required for growing businesses in today’s world.
Remote Monitoring Solutions
If you need the flexibility to oversee and manage your monitoring system from just about anywhere, you might be better off with one of our remote monitoring system solutions. These advanced cloud-based systems provide off-site remote monitoring capabilities and remote alerts, reports, and diagnostics, reducing your need to pay for on-site supervision. This option is ideal for most businesses in the modern age, and we have solutions to suit those with multiple business locations.
Smart Factory Integration
Our most advanced compressor monitoring system can be integrated with multiple compressors and many of your internet-enabled devices thanks to Internet of Things (IoT) technology. Using one central controller, such as the Optimizer 4.0, you could gain the power to remotely manage, oversee, and optimise almost all your advanced tools and equipment. While these may be the most expensive systems to purchase, they offer unrivalled long-term savings and help you maintain consistent air pressure across complex networks.
If you need help determining which type of system will best suit your needs, give us a call. We have been industry leaders for decades, and no task is beyond the scope or capabilities of our seasoned experts.
Atlas Copco’s Latest Systems
We are excited to be among the UK’s most trusted suppliers of Atlas Copco equipment because it proves our commitment to settling for nothing but the best for our clients. We have the latest cloud-based SMARTLINK solutions in stock right now that allow you to check on your compressed air systems while on the move.
SMARTLINK offers three tiers of service to ensure the status of your compressed air is always visible:
- SMARTLINK Service: Streamlines maintenance scheduling and provides service status updates.
- SMARTLINK Uptime: Sends alerts for critical parameters, helping you protect the reliability of your compressed air equipment.
- SMARTLINK Energy: Provides deep insights into the efficiency of the compressed air system, helping you audit energy usage and ensuring compliance with ISO 50001.
You can track the performance of your compressor using a tablet or smartphone. We also stock the advanced range of SMARTVIEW systems, which connect to a central controller of your local area network. These systems are ideal for large enterprises where in-depth technical analysis is required.
For businesses operating mixed fleets, we can also advise on universal monitoring systems that consolidate data from various manufacturers into a single dashboard.
A guide to Air Compressor Monitoring Systems
Benefits of Air Compressor Monitoring Systems
Installing a right air compressor monitoring system offers a range of tangible benefits that go far beyond fault detection. These innovative solutions can drive meaningful improvements across your entire compressed air system:
Improved energy efficiency
Real-time monitoring and energy tracking enable you to identify inefficiencies, leaks, and pressure drops across your air supply. This allows you to make timely adjustments and significantly reduce your system’s overall energy consumption. Monitoring systems simplify the process of identifying expensive air leaks, which can waste up to 30% of your generated power.
Enhanced system reliability
Monitoring critical parameters like air pressure, temperature, and vibration helps ensure your compressed air equipment operates within safe limits. By spotting early warning signs of wear or malfunction, you can act proactively, improving the reliability and consistency of your compressor performance.
Predictive maintenance planning
Monitoring systems track trends over time, making it easier to schedule servicing based on the actual condition of your equipment rather than relying solely on fixed intervals. This predictive approach reduces downtime, avoids emergency repairs, and extends the lifespan of your assets.
Remote management and flexibility
With remote access capabilities, you can check in on your compressor systems without needing to visit the compressor room. Whether you manage a single site or multiple locations, a smart air compressor monitoring system gives you complete visibility and control from your smartphone, tablet, or central air compressor controls.
Greater workplace safety
By constantly overseeing conditions such as excessive temperatures, air flow fluctuations, or sudden pressure spikes, monitoring systems help maintain a safe working environment and reduce the risk of costly accidents.
Support for sustainability goals
Maintaining air quality with pre-filtration mats and high-efficiency air filters and pre-filtration can reduce unnecessary energy wastage. Our systems can monitor the condition of your air filters and pre-filtration mats, ensuring optimal airflow. Monitoring your air compressor system more closely can help businesses meet sustainability targets and improve environmental compliance with standards like ISO 11011. Properly maintained mats and high-efficiency air filters also protect downstream equipment.
If you would like to learn more about the measurable benefits of choosing the right system for your operation, we are only a phone call away.
Common Challenges & Solutions
Implementing a new system can come with challenges, but the right approach ensures success:
- Data Overload: Modern sensors generate vast amounts of data. Using dashboard filters in systems like SMARTLINK allows you to focus only on actionable insights.
- Connectivity: Industrial environments can be tough on Wi-Fi. We recommend cellular-based gateways or robust local networks to ensure you never lose sight of your system.
- Mixed Equipment: Many facilities use air compressors using different technologies or brands. A central controller can unify these disparate systems.
UK Compliance & Legal Considerations
Staying compliant is a major reason to invest in monitoring. Under the Energy Savings Opportunity Scheme (ESOS) Phase 4, large UK undertakings must now provide actionable plans for energy reduction. An air compressor monitoring system provides the verified data required for these reports. Additionally, the Data (Use and Access) Act 2025 empowers you to access diagnostic data from your equipment, ensuring you are never locked out of your own system’s intelligence.
Discover Our Selection of Compressor Monitoring Solutions
At Search Air, we have been supplying, installing, maintaining, repairing, and upgrading the most advanced compressor monitoring systems by Atlas Copco for over two decades. In addition to the most advanced and energy-efficient solutions on the market, we boast a team of highly experienced engineers and technicians, high-value prices, and unparalleled customer service. Call us for your compressor needs, and you will have a dedicated partner for life.
Whatever your setup, managing a compressed air system without proper oversight is a financial risk. Whether you have a few questions or need a technician to visit your site and assess your requirements, we hope to hear from you for a no-obligation chat. We can help you navigate the options for air monitoring and finding the right system for your needs. Contact us today, and we look forward to telling you more about the cost-saving benefits of our compressor solutions and how you can reduce costs by maintaining consistent air pressure.
Learn how air compressor monitoring can transform your business today.
FAQs
What are the main benefits of using a modern air compressor monitoring system?
A modern air compressor monitoring system helps improve the efficiency of your compressed air system by tracking key parameters like air pressure, energy use, and temperature in real time. These systems also support predictive maintenance, enhance workplace safety, and help extend the lifespan of your compressor equipment while reducing energy costs.
Can I monitor my compressed air system remotely?
Yes, advanced systems like remote compressor monitoring solutions allow you to check in on your compressor and its performance without needing to visit the compressor room. You can access real-time monitoring and alerts from your smartphone, tablet, or central air compressor controls, giving you flexibility whether you manage one site or multiple locations.
How do I choose the right monitoring system for my compressed air setup?
Choosing the right monitoring system depends on factors such as the size of your air supply network, the number of compressors, and whether you need smart features like remote access and predictive maintenance. For example, a simple workshop may only need a local Elektronikon® controller, while a large pharmaceutical plant might require a full SMARTLINK setup for ISO compliance. Selecting a system compatible with your existing compressor equipment is important and helps ensure your compressed air system operates reliably and efficiently.
Is air compressor monitoring required for ISO 11011?
While monitoring itself is not the standard, ISO 11011 is the assessment standard for compressed air system energy efficiency. To accurately conduct this assessment and maintain compliance, continuous data logging from a monitoring system is practically essential.
What is SMARTLINK and how does it work?
SMARTLINK is Atlas Copco’s remote data monitoring system. It connects your compressor’s controller to the cloud, allowing you to view performance data, receive maintenance alerts, and analyse energy efficiency from any internet-connected device.