How to Make Your Air Compressor More Efficient
How to Make Your Air Compressor More Efficient
Air compressors have become an indispensable part of businesses around the UK as they can be used in a wide range of sectors. Whether it is manufacturing plants, food production or for use in the automotive industry, air compressors are an excellent tool power source. Still, there is always more that can be done to ensure maximum efficiency.
An efficient air compressor will deliver lower energy bills, boost productivity, reduce the need for maintenance, and be more environmentally friendly overall.
There are various types of air 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 the most efficient types. However, rotary vane and piston air compressors have advantages for certain tasks.
Variable speed drive (VSD) air compressors are gaining in popularity, too, thanks to their ability to adjust the output based on fluctuating demand.
Whatever air compressor you use, there are always ways to make it run more efficiently. We will explore the top five methods for improving the efficiency of your air compressor.
Frequent maintenance
Air compressors require regular maintenance to keep them functioning at their best – like any other machinery. An air compressor maintenance check helps identify minor issues before they escalate into major problems, which are more costly to fix.
During a maintenance check, a qualified technician can test the seals, clean out or replace air filters, check the belts, add lubrication if needed, and detect leaks. These things together add up to a finely tuned machine capable of performing much more efficiently.
How regularly your air compressor needs maintenance depends on factors such as the size of the 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 of your air compressor system as it is possible to reduce the pressure and still benefit from the same performance. Many systems have the pressure set too high, which has a knock-on effect on the cost of energy it uses.
You save a lot of energy for every bar of pressure you reduce in the system. So, it is best to alter the pressure according to the task or when the air compressor is used less frequently.
Pressure drops 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. 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 to resolve any of these issues and restore efficiency quickly.
Upgrade your system
Brand-new air compressors have many energy-efficient features that give you the best performance. A more efficient motor 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 system and pressure regulators can be upgraded and swapped for new models with proven energy-saving benefits. Energy use can be reduced drastically by using a VSD air compressor, which alters the output according to demand.
Upgrading your air compressor does not have to be expensive. Sometimes, small changes can make a big difference. New tubing and valves, for example, do not cost the earth but can help to keep your 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 and bends reduce efficiency, and you can even consider changing the diameter of pipes to get the most out of your air compressor.
Installing 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 system efficiency.
The design and installation of a new system can have a large initial outlay but, in the long run, your business will save money every time the equipment is used.
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 is the best way to determine your system’s overall health and ensure there are no leaks or parts that need replacing. If your system is still not performing as efficiently as you would like, you can discuss further options like system upgrades, system optimisation, and new parts with a qualified engineer.