Compressed Air – Saving Energy and Operational Costs

Key Objectives

The Challenge

This company was looking for a cost-saving solution for its manufacturing facility. In order to identify these savings, we conducted a detailed air energy audit to determine the current operational costs, energy consumption, and electricity usage of their current fixed speed compressors. With this data, we were able to forecast that we could give them an approximate saving of between 27-29%

The Solution

We removed the three exisiting fixed speed compressors and replaced them with two variable speed compressors, programmed to run in a duty/standby configuration. The variable speed technology eliminates off-load running of the compressors whilst meeting the same air demand and this produces immediate energy savings. As the compressors only run when production demands, the operating life is also increased and servicing costs can be reduced. The twinned units and alternate operating pattern not only give 100% back up but also equalise running hours and allows co-ordinated serving. The actual energy saving achieved far exceeded the original prediction. Reduced noise levels and the recovery of hot exhaust air to heat the factory were additional benefits.

The Result

“I am thrilled with the results from the installation of a new compressor system from CPA. The 42% energy savings achieved with this solution have far exceeded my initial expectations”

Engineering Manager