10 Tips to save you energy in your compressed air system

Follow these ten steps for energy savings in your compressed air system.

1. Turn off compressors when not needed

A 100 hp compressor can cost $75,000 per year in energy costs (based on 8,760 hours at 0.10 per kWh).

2. Identify and fix leaks

ultrasonic leak detection service

Leaks waste a lot of money. Even fixing a few major leaks helps the bottom line.

3. Eliminate inappropriate use of compressed air

Using compressed air for blow off is not only wasteful, it can be dangerous as well. Did you know that using air over 30 psi for blow-off is actually an OSHA violation?

4. Apply proper controls to multiple compressor systems


Master system controllers maintain a stable system pressure and ensure that only the needed compressor units are brought online and that they are operating at peak efficiency.

5. Ensure piping and storage are adequately sized

compressed air receiver tank at large installation, compressed air systems, compressed air storage tanks

Many systems lack adequate storage. Kaeser recommends both a "wet" and "dry" tank. Undersized piping will increase pressure drop in the system.

6. Change your filters routinely to eliminate pressure drop

compressed air filters by Kaeser Compressors

Every 2 psi in pressure drop costs 1% in compressor horsepower efficiency.

7. Use automatic, zero-loss condensate drains

ECO-DRAIN electronic condensate drain

Capacitance sensor-operated drain traps don't need to be monitored. They discharge only condensate, not valuable compressed air.

8. Apply variable speed drive compressors where appropriate

SFC15 air system

Variable speed drive is not a "one size fits all" solution. But if you have varying demand it can save you thousands on electricity costs each year.

9. Reduce operating pressure to lowest possible setting

For every 2 psi reduction in system operating pressure you save 1% in compressor efficiency.

10. Recover waste heat from coolers

Maximum heat recovery with rotary screw compressors.

A 50 hp compressor rejects heat at approximately 126,000 Btu per hour.