10 Step Guide to a Greener and more Efficient Production

It pays to do the right thing

Compressed air production consumes a large amount of energy, which impacts a company’s bottom line as well as the environment.

However, there are some things businesses can do to immediately and sustainably make compressed air generation less expensive and more environment friendly.

This 10-step guide will help companies lower their energy consumption and carbon footprint, which will translate into direct savings. In some cases, these savings will be substantial.

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1. Application & Installation

Before expanding, replacing or improving an existing compressed air system, you should first look to eliminate waste in the current system.  The majority of compressed air systems in use today are inefficient and because of this, often limit their own productivity and product quality.

- Isolate any production equipment that is not in use to reduce the potential for equipment leakage. - Keep your working pressure as low as possible. A higher working pressure means a higher power requirement and, as a result, higher energy costs and a larger carbon footprint. - Manage your leakage. Leaks may cost you significant amounts of capacity and money each year. - Keep your compressor cool and clean. Every 5°C rise in air temperature results in a 2% loss in efficiency, so keep your compressors cool!

2. Storage & Distribution

- The size of the air receiver and pipework can directly impact energy consumption. Air receivers reduce the cycling time of air compressors, which increases their reliability and longevity.

- As operations grow, increase the size of the main distribution pipework diameter or convert a dead-end pipework system into a ring main pipework system.

- The simplest and most effective thing you can do to increase the efficiency of your compressed air network, save money and reduce your carbon footprint is to plug any air leaks in your system.

3. Air Quality

You should always know which air purity your applications require.

- By selecting the correctly sized air treatment products, you can minimize the pressure drop, which will reduce your compressor’s power consumption.

Dryers play a major role in the production of high-quality air.

- They eliminate the moisture it contains and thereby protects the downstream equipment. However, they also greatly contribute to the energy consumption of such a system.

4. Volume & Flow Pattern

Understand your air demand.

- If you eliminate the inefficiencies of your compressed air network, your next compressor may need to be a lot smaller than you think – or you may not even need a new one at all / just yet.

When investing in a new compressor, make sure to be aware of the flow patterns within your operation and operational shifts also have to be taken into account. Even the most efficient compressor may not be your most profitable solution in all cases.

5. Core Technology

The right investments will pay off over time.

- Keep in mind that energy expenses make up the vast majority of the total cost of ownership of a compressor or other compressed air equipment. These costs dwarf the initial investment and all maintenance costs. So do not let a high price tag scare you. If you buy cheap compressed air equipment, you will pay more in the end – and harm the environment in the process.

There are many different types of air compressor, and each have different advantages based on the operating pressure and air volume requirement e.g. Piston compressors, Scroll compressors, Tooth compressors, Screw compressors, Centrifugal compressors.

6. Equipment Control

It is very important to keep in mind that, while the efficiency of your compressor is the foundation for the efficiency of your entire compressed air network, there are other important factors as well. You can only get the most out of your system – and therefore enjoy maximum savings – if you select a control system that matches your needs. There are different methods of control – and once again it depends on the flow pattern to determine which one is best for you.

Advanced controllers, such as our Elektronikon®, can help you manage your pressure and optimize your power consumption with smart algorithms designed to minimize power consumption.

7. System Control

You should consider the use of a smart, central controller that accommodates different compressor technologies and control types to maximize energy efficiency, your savings and reduce your carbon footprint.

Our Optimizer 4.0 is a perfect example. It will not only prioritize the best compressor(s) for any situation but also increases the efficiency of the operation within the whole system by using the most optimum points possible, while reducing maintenance costs and helps you record your machine data.

8. Energy Recovery

Compressing air generates a lot of heat. In fact, over 90% of the electrical energy a compressor uses is converted into compression heat. If you allow that heat to go to waste, you are literally allowing money to vanish into thin air. That is why energy recovery is the single best thing you can do to reduce your energy consumption.

Instead of wasting it, you can use that heat to warm your factory in the summer, cool it in the winter or even turn it into electricity.

Of those three methods, heat-to-heat is the most efficient with a 90% energy recovery rate. Heat-to-cold can get you a 60% recovery rate while heat-to-electricity yields a 10% return, which still beats just letting this potential energy source go to waste.

9. System Maintenance

It is very important for companies to view maintenance as an essential component of an energy optimization system and not as a burdensome chore that sometimes shuts down production.

In the end, a well-maintained compressed air system will more than pay for the maintenance costs through energy savings.

10. Remote Monitoring

Remote monitoring is an extremely useful tool that helps you to always keep an eye on your compressor. It allows you to optimize your equipment’s performance from anywhere and receive messages alerting you to potential issues.

SMARTLINK

- SMARTLINK Energy recommendations are uniquely based on the working parameters and performance of your compressed air installation. They show real opportunities and give practical advice to further improve the efficiency and reliability of your system.

Alerts can be sent to your computer or smartphone, and if reducing energy consumption is your priority, SMARTLINK helps you with customized reports.

Green production