10 Steps You Can Save on Air Consumption

Looking at ways to save on energy costs, reducing CO2 emissions?  Maybe it is time to take a closer look at your compressed air system? 

Westcomm Equipment can help determine the best places to start and work with you to address these concerns.  For now, here is a top ten list of where you can start. 

  1. Turn it off  

Most compressed air systems only run 60 to 100 hours per week depending on your shift pattern, make sure to shut your compressor off when production is off, evenings, weekends, etc. 

  1. Fix Air Leaks 

A quarter inch air leak at 100 psi can release up to 100 cfm, this will cost thousands of dollars per year.  Anytime air is leaking, through fittings, rubber hoses, worn quick connects is money wasted. 

  1. Prevent New Leaks 

Look inside your piping distribution system, clean dry pipe is what we want to see.  If  you see dust, moisture or sludge, these are signs that something is wrong.  We need to address filtration and drying.  Any of these conditions will lead to excessive corrosion in your distribution system and help create leaks. 

  1. Reduce Pressure 

We will work with you to determine the best pressure to operate at.  Every 2 psi in pressure reduction equals a 1% reduction in motor horsepower.  Pressure reduction can be achieved in the distribution system as well, clogged filters, corroded pipe, improper pipe system design can also all contribute to pressure drop. 

  1. Condensate Drains 

Are drains stuck open? Timers adjusted correctly?  Or can timed drain valves be replaced with zero loss drain valves? 

  1. Piping and Distribution System 

Your pipe system should deliver consistent flow and pressure from the compressor discharge to point of use.  Is the pipe the correct diameter for the volume of air being used?  How long does the air have to travel to point of use?  Increasing pipe diameter and proper plant layout will help reduce pressure drop. 

  1. Change Filters Systematically 

Inspect and replace filters systematically, clogged filters will lead to poor quality air and increased pressure drop.   

  1. Recover Heat 

Air compressors generate a lot of heat, this can be reused for a number of purposes, drying racks, producing hot water, or building heat.  Upwards of 90% of heat from the compressor can be reused. 

  1. Proper and Timely Maintenance 

Your compressor will run more efficiently when it is properly maintained.   A proper maintenance program will also help prevent breakdowns resulting in less downtime, and lost production.   

  1. Eliminate Improper Uses of Air 

Inappropriate uses of air contribute to significant operational costs.  Using air to clean up work space, blow off clothing, not only wastes compressed air but is also a safety issue.   

Working with Westcomm Equipment, we can provide onsite consultation to help reduce costs, improve efficiency, and keep your air system and production running smoothly for years to come.