Would you like to reduce the electrical costs associated with your compressed air system? Chances are you can. Start by determining your annual compressed air electrical costs using this formula:

Brake Horsepower X 0.746 X Annual Hours of Operation X KWH (Kilowatt Hours) Cost (divided by) Motor Efficiency

NOTE: 1 CFM (cubic feet per minute) at 100 PSIG (pounds of force per square inch) PER 8760 HOURS COST $110.00 PER YEAR ELECTRICAL COST

Next… follow these top 7 tips to save energy with compressed air:

1. Fix your air leaks

If you do nothing else, follow this advice: find and fix your compressed air leaks. Air leaks are the “biggest loss” in the industry!

The average plant loses 20-30% of its compressed air through multiple small air leaks. The money spent on labor and parts to find and fix these leaks is well worth it. Note (1/4 inch orifice will flow 103 cfm at 100 psig)

2. Change to Synthetic Lubricants

If you are using petroleum-based lubricants, you could experience up to 8% energy savings by switching to synthetic compressor lubricants. Plus, extend equipment life and save on oil changes and disposal costs.

3. Reduce plant operating pressure

If possible, reduce overall plant pressure. Less pressure > Less CFM used > less energy consumed.

TIP: Reduce plant pressure 2 pounds at a time, then test run for a minimum of 24 hours. If any equipment has problems… increase the pressure 2 pounds until it works smoothly again. For every 2 pounds of pressure reduction, you save 1% of the electrical cost to run the air compressor.

4. Check differential pressure across air compressor filters.

Start at the compressor cabinet filter and then check the compressor inlet filter.

Note: A dirty inlet filter can cost you 1-3% in additional electrical costs. Why? Because decreasing airflow to the compressor inlet valve increases compression ratios, resulting in more run time.

Next, check the differential pressure of the air/oil separator at full load. A new separator causes a differential pressure drop of approximately 2-3 psig. When your pressure drop reaches 8-10 psig, then it’s time to change the separator elements. A dirty separator element can cost you up to 5% in additional electrical costs.

Next, replace the control air filter element. This is often overlooked, but it’s still an important filter where the controls get their air signal. A pressure drop here causes the controls to receive the lower pressure signal loading the compressor more and using more electricity.

5. Reduce compressor inlet temperature

By reducing the inlet air temperature 10°F below 70°F, you save 2% on electricity use. Your benefit increases up to 8% on a 30°F day. But increasing the inlet temperature 10°F above 70°F will cost you 2% in additional electrical usage for every 10°F up to 10% at 120°F. (Inlet temperature has little effect on lubricated screw compressors)

6. Check pressure differential across compressed air line filters.

Size compressed air filters to be twice (2x) the CFM flow rate of your compressor. This will reduce your pressure drop by approximately 2-3 psig and save 1% on energy costs. The elements will last twice as long (2x) and you will save on maintenance costs.

7. Know what quality of compressed air your plant needs.

The cleaner and drier the compressed air, the more energy is used.

Check with your equipment manufacturer to determine the air quality needed.