Fixed-Speed to VSD Upgrade Saves £14,000 Annually
How a UK SME Manufacturer Improved Efficiency Without Compromise
With rising energy costs and ageing equipment, a UK-based SME slab manufacturer reached out to Search Air for support. Their existing fixed-speed compressor was struggling to meet day-to-day production demands, resulting in wasted energy, fluctuating air pressure, and escalating operating costs.
The Challenge
The client’s fixed-speed compressor delivered a constant air output regardless of demand. This meant the system consumed power even during periods of low usage, leading to unnecessary energy expenditure.
The Solution
Our technical team conducted a full system analysis to assess real-time air demand and load patterns. This revealed significant inefficiencies that could be corrected through modernisation.
We replaced the legacy system with a state-of-the-art Atlas Copco GA75L VSD+ compressor. Equipped with Variable Speed Drive (VSD) technology, this unit dynamically adjusts motor speed to match actual air demand, reducing energy waste and improving pressure stability across all operating conditions.
To ensure long-term peace of mind and predictable maintenance costs, the client also opted for a 7-year Guardian Service Plan, offering fixed-price servicing throughout the lifecycle of the equipment.
Fixed-Speed to VSD Upgrade Saves £14,000 Annually
The Results
The benefits of the upgrade were immediate and measurable:
- £13,619 annual energy saving – verified at 22% reduction
- Payback period of just 26 months
- Carbon footprint cut by 65,552 kg CO₂ per year
- Improved reliability and system responsiveness
- Lower lifetime operating costs with VSD efficiency
- Hassle-free maintenance with Guardian fixed-price service
This project underscores how modernising compressed air infrastructure doesn’t have to mean compromising operations. With intelligent system design and energy-efficient technology, significant savings and sustainability gains are possible even for smaller manufacturers.
Why Choose Search Air?
As an employee-owned business with decades of expertise, Search Air offers honest, long-term advice and delivers tailored solutions backed by reliable service and industry-leading technology.
We’re proud to be an Atlas Copco Premier Distributor, and our team is committed to helping clients reduce costs, cut emissions, and improve operational performance.
Thinking About Upgrading?
If your compressed air system is outdated, oversized, or struggling to keep up with production, now’s the time to act.
📞 Book your FREE airCHECK today
Let’s uncover where your savings lie.
📧 air@wgsearch.co.uk
📞 Leeds: 0113 263 9081 | Nottingham: 0115 986 1141 | Sheffield: 0114 244 6521
🌐 compressive.co.uk