How to increase air compressor efficiency: Industrial guide

The use of compressed air and specialty gases is crucial for industrial settings ranging from breweries and food production to automotive and manufacturing. Thus, finding ways to increase air compressor efficiency leads to significant energy savings, reduced maintenance costs, and increased productivity.

 In this guide, you’ll learn five ways to proactively increase air compressor efficiency. We’ll also provide maintenance best practices to prevent damage and system downtime. Finally, you’ll find answers to some common questions about air compressor energy efficiency.

Five ways to increase air compressor efficiency

Five important strategies to increase air compressor efficiency:

1. Avoid idling compressors
2. Improve air intake quality
3. Update system design
4. Monitor for pressure drops
5. Detect and repair air leaks

1. Avoid idling compressors

An idling compressor uses around 40% of its full load. Switch off compressors when they're not in use, especially overnight or during breaks. This can make a significant difference in energy consumption.

2. Improve air intake quality

The quality of intake air plays a pivotal role in the performance and efficiency of your air compressor system. Three primary components influence this:

• Temperature: Cool air requires less energy to compress, making it more efficient. Avoid using hot air with lower density, as it could diminish productivity.
• Composition: Clean intake air ensures smoother movement of compressed air through the system. Dirt or contaminants can accumulate inside, causing wear and reduced storage capacity. Regular maintenance and cleaning can improve air composition, thereby enhancing efficiency.
• Humidity: Dry environments are optimal for compressed air systems. Moisture within the system can cause components to rust, leading to wear, leaks, and reduced storage capacity.

3. Update system design

An efficient compressed air system depends on its design. By optimizing the design, you ensure maximum efficiency. Aspects to consider are:

• Control System: Demand control, storage, compressor controls, strong signal locations, and an overall control strategy. This helps deliver compressed air at the lowest stable pressure. Sequencing controls for multiple compressors can also balance system loads.
• Load Profiles: A system that accommodates variations in air demand can work efficiently even under part-load conditions. This strategy can be especially energy efficient when there are significant fluctuations in demand.
• Minimize Artificial Demand: Ensuring that applications only get the air volume and pressure they require reduces waste. Regulating pressure at the end-use can minimize artificial demand, preventing overuse of the system.

4. Monitor for pressure drops

Pressure drops result in decreased performance and increased energy consumption. A pressure before the compressor signal creates a lower operating pressure for end-users.

5. Detect and repair air leaks

Systemic air leaks can waste up to 30 percent of a compressor’s output. This increases energy costs and causes breakdowns that increase downtime. Regularly monitoring system pressure and taking a proactive approach to detecting compressed air leaks can lead to substantial energy savings.

Detecting and addressing pressure drops and air leaks early, along with keeping equipment properly maintained, can prevent these problems. We’ll explore these in more detail below.

Compressed air efficiency: Maintenance best practices

Proper maintenance extends the life of a compressed air system, boosts its productivity, and enhances its efficiency. We’ve grouped maintenance best practiced for compressed air efficiency into four groups:

1. Change filters regularly
2. Maintain proper belt tension
3. Inspect and optimize moving parts
4. Conduct regular leak detection

1. Change filters regularly

Over time, air and oil filters can become clogged with dirt and debris. These conditions lead to reduced efficiency and potential damage. This causes resistance, making the compressor work harder and consume more energy.

Action items

• Change or clean every three months or 500 hours of use
• Inspect related components like pulley nuts and screws at that time
• Always have spare filters on hand to prevent operational downtime.

2. Maintain proper belt tension

A belt that is excessively tight can result in heightened wear on both the belt and the motor bearings. A loose belt may slip, causing reduced compressor output and inefficiency.

Action items

• Inspect belts weekly wear or misalignment.
• Adjust belt tension to optimal operational conditions.
• Replace worn-out belts promptly

3. Inspect and optimize moving parts

Perform regular inspection of components including the safety valves, hoses, and electrical connections. Keep all moving parts lubricated to avoid friction. This ensures smooth, efficient operation while preventing energy losses and breakdowns.

Action items

• Use lubricants recommended by the compressor manufacturer.
• Regularly check lubricant levels and replenish as needed.
• Monitor for any signs of lubricant contamination.

4. Conduct regular leak detections

As previously mentioned in the first section, leaks are a significant source of energy wastage in a compressed air system. Regular leak detection substantially reduces energy costs and increases the compressor’s lifespan.

Action items

• Utilize ultrasonic leak detectors to find leaks
• Install air flow meters with IO-Link technology for real-time data and alerts
• Regularly inspect fittings, valves, pipes, and joints.
• Repair detected leaks promptly to maintain system efficiency.

Air compressor energy efficiency FAQs

Why do compressors use so much electricity?

Compressors use a considerable amount of electricity mainly because compressing air is an energy-intensive process. Every time the system compresses air, it uses energy to overcome atmospheric pressure. The process also generates heat, which requires more energy to manage.

Are compressors energy efficient?

With proper management and maintenance, compressors can be energy efficient. The efficiency largely depends on the design, maintenance regimen, and usage pattern. Modern compressors with optimized designs and control systems are more energy efficient than older models.

Is it better to leave an air compressor on?

No, it's not advisable to leave an air compressor running when not in use. Constantly-running compressors, especially in idle mode, still consume significant amounts of energy. Industry best practices are to turn off the compressor during long breaks or when not in use to save energy.

What is the life expectancy of an air compressor?

The life expectancy of an air compressor varies based on its design, quality, usage pattern, and maintenance. On average, industrial-grade compressors have a lifespan of 10 to 15 years. Regular maintenance and timely repairs can significantly extend this duration.

Can you overwork an air compressor?

Running a compressor continuously, especially beyond its designed capacity or without adequate breaks, will overwork the machine. This leads to overheating, increased wear and tear, and reduced lifespan.

What is the minimum compressor off time?

The minimum off time for a compressor varies depending on its design and capacity. However, most manufacturers recommended at least 15 minutes of rest between cycles. This regimen prevents overheating and extends the equipment's lifespan.