Compressed air systems are an integral part of most industrial plants - from food production to the woodworking industry to the automotive industry. Although they are irreplaceable, they have one major drawback: they can generate very high electricity costs. It is estimated that as much as 70% of the total cost of running a compressed air system is the energy consumed by the compressors.
The good news is that there are many ways to reduce these costs - often without a large investment, and sometimes by upgrading selected elements of the installation. In company Marani We have been advising customers on how to optimise their pneumatic systems for years, and in this article we present the most effective solutions.
1. Identify and eliminate leaks
The simplest and at the same time most underestimated source of energy loss is leaks in installations pneumatic. In many plants, up to 20-30% of the total compressed air volume escapes through leaks. It's as if some of the medium produced is being 'released into the air' and we are paying for it.
At Marani we offer pneumatic auditsduring which we locate leaks using ultrasonic detectors. This enables installations to be sealed quickly and energy losses to be significantly reduced.
2. replace a fixed-speed compressor by a variable-speed compressor (with inverter)
One of the biggest breakthroughs in energy optimization is the replacement of the classic fixed-speed compressor by a model with a variable speed (so-called VSD - Variable Speed Drive). A conventional compressor runs at full power or in what is known as "slack gear" when compressed air is not needed - both of which consume a large amount of energy.
The variable-speed compressor adapts its speed to the current air demand. Thanks to this virtually eliminates costly idlingand its operation becomes much more energy efficient. In many cases, savings are as high as 30% per year, with the investment in a modern compressor paying for itself within 1.5-2 years.
Marani offers the selection, supply and installation of VSD compressors tailored to a plant's specific operating profile. We also offer hybrid systems, combining fixed-speed and variable-speed compressors into intelligent air management systems.
3. Reduce system pressure - but with your head
Many plants operate at higher pressures than necessary. Each 1 bar excess pressure is an increase in energy consumption of up to 7-10%. Reducing the pressure to the actual operating minimum brings immediate savings. However, care must be taken - pressures that are too low can affect the operation of machinery and processes.
The solution may be to divide the system into zones with different pressures or to install air buffer tanks. At Marani, we help our customers optimise the operating pressure by analysing consumption and adjusting system parameters accordingly.
4. use compressor heat recovery
When air is compressed, a considerable amount of heat is generated which is mostly simply lost. And yet it can be recovered! Heat recovery systems allow waste energy to be used to heat domestic water, support hall heating or other technological processes.
It is an ecological and economical solution - the investment in a heat recovery module can pay for itself within one heating season.
5. regular maintenance and technical inspections
Negligence servicing of compressors, dehumidifiers or filters results in a decrease in efficiency and an increase in energy consumption. Example? A dirty air filter can increase the flow resistance and thus increase the load on the compressor. Regular maintenance keeps the system in optimum condition and avoids unplanned downtime.
Summary
Reducing energy consumption in a compressed air system is a process that starts with measurements and ends with appropriate investments. In many cases, fixing leaks or correcting pressure is enough, but the real savings come from compressor upgrades - including conversion from a fixed to a variable speed compressor, eliminating costly bulk running and significantly reducing electricity bills.
W Marani we offer not only products, but above all tailor-made solutions. We support customers in optimising their pneumatic installations - from audit to design to implementation and service. Contact us if you want to reduce the costs of your installation and increase its reliability.
