Of course, the initial investment in a new compressor is often very expensive. But in the life cycle, the operating costs are more important. These include above all the energy used, but also the costs for maintenance and spare parts that are incurred during the life of the compressor. We have summarized for you in this text what you need to budget for this.
Of course, the initial investment in a new compressor is often very expensive. But in the life cycle, the operating costs are more important. These include above all the energy used, but also the costs for maintenance and spare parts that are incurred during the life of the compressor. We have summarized for you in this text what you need to budget for this
Small costs, big impact: Why compressor maintenance is often underestimated
Like all other machines, the compressors that supply compressed air to production machines and processes also require regular maintenance. This ensures that they run reliably and efficiently throughout their service life. Compared to other costs associated with compressed air stations - especially those for energy - the costs for maintenance and servicing are low. Roughly speaking, you should allow for between 5 and 10% of the total investment sum per year for maintenance. For very small systems rather more, for very large systems also less. The intensity and frequency of the maintenance depends, among other things, on the conditions at the site and on the reliability requirements of the compressed air system. In the worst case, a failure can cause the entire production to come to a standstill. Compressor failures are particularly critical in the continuous processes of the chemical and petrochemical industry and in similar applications, but also in sewage treatment plants whose aeration tanks must be continuously supplied with air.
Such examples make it clear that it can be expensive to save on maintenance and servicing. "Going on crash" is not an option for companies. In a single day, unplanned downtime due to a failed compressor can result in costs that significantly exceed the maintenance costs for an entire year. Regular maintenance of the compressed air system ensures that wearing parts, for example, are replaced in good time before a - then costly - repair becomes necessary and production comes to an unplanned standstill.
These points can cause costs if maintenance is saved:
- Unnecessarily high energy consumption
- Production downtime
- Security Issues
- Acquisition and installation costs for new machines
Reduce costs through sensibly planned compressor maintenance
Those who plan the preventive maintenance of their compressors and air treatment components increase the service life and reliability of the system. And costs are reduced if unplanned downtimes and repairs are avoided. Which maintenance measures are required at what time depends on the plant and the operating conditions: Do the compressors run in continuous operation? Are the machines exposed to dust and heat? The current compressor series from Atlas Copco, for example, are also available in weatherproof design and for extreme ambient temperatures.
The specific maintenance dates, for example, can be scheduled for times when production is at a standstill anyway. If expert technicians replace wear parts with original components in good time, the machines are maintained at a high technical level. As a rule, Atlas Copco's trained maintenance experts recognize even small signs of problems before they can lead to a breakdown. Depending on the service agreements that users can sign with Atlas Copco, they also benefit from further developments in compressor technology: for example, the installation of the latest drive elements and compressor stages can restore the efficiency of a new machine. Please also read our notes on general overhaul of compressors.
When maintenance solutions are tailored to the compressor workload, application and site conditions, the total cost of ownership is reduced by an average of 35%. Businesses save on their own staff and electricity bills because a poorly maintained compressor consumes more energy to produce the same amount of air as a properly maintained machine. Preventive maintenance by experts ensures that the machines continue to run at maximum efficiency. This also reduces the risk of downtime. The somewhat higher costs for the service, which arise when maintenance is carried out by an external provider, are hardly significant in comparison.
If a failed compressor leads to unplanned downtime, costs can be incurred on a single day that can significantly exceed the maintenance costs for an entire year. With the right maintenance solution, however, you can significantly increase machine availability!
In addition to the compressed air system, other components such as dryers and filters also require maintenance. Drying agents and filters must be replaced regularly. The maintenance costs involved also depend on the operating conditions and equipment; they must be added to the total maintenance costs.
The optimal service agreement for every requirement and every budget
Atlas Copco offers various service packages to meet the individual needs of companies for their plant safety. From the basic service package to the all-round carefree solution, the right one can be selected from various contracts. For optimum availability and efficiency of the compressed air supply, users can have their compressors monitored using Atlas Copco's SmartLink software. The system issues warnings based on the compressor operating data. Problems are identified by analyzing this data before they occur or before repairs are necessary.
- Read here how service contracts can be compared and what companies should pay particular attention to
- Click here for our service request form for Atlas Copco compressors
- Service request form for the maintenance of third-party machines
How can different service contracts for compressor maintenance be compared?
You have different maintenance offers to compare? Our checklist provides information on how to compare different service contracts. Click here for a free download:
Which services should be covered by a service contract?
Download the checklist now free of charge
