Maximize Efficiency for Compressed Air Systems

Compressed air systems can help with a wide range of industry jobs and benefit your company in many ways. Compressed air systems will help complete applications faster and improve the efficiency of your plant.

There are many ways to maximize the efficiency of your compressed air system. By performing regular maintenance and observing energy saving tips, you will be able to get the most out of your compressed air system. These practices will allow your system to conserve energy and save on costs.

Find Your Ideal Max Operating Pressure

One way to maximize efficiency is by controlling the amount of air pressure sent through your compressed air system. Certain applications will require a higher level of air pressure, while others will require much less pressure to complete the job. If you constantly run your compressed air pipe system with high pressure, you could potentially be throwing away thousands of dollars each year.

The best solution to this problem is to determine the best max operating pressure for your system. You can do this by calculating the minimum amount of delivery pressure needed for each job. After you discover the highest minimum pressure used in your system, you can set this number as the maximum control pressure allowed for use in your system. That way there is enough air pressure to get every job completed without powering the system for extraneous pressure.

While this will require some initial testing, it could save you big on expenses in the long run. Keep a record of every test completed and any other changes made within your system. With detailed record-keeping, you can avoid having to run a test multiple times, which will also help you save on your energy usage.

Retrofit Old System Parts

Some parts of your compressed air system may require a higher amount of pressure than others to operate. Many of these parts can be retrofitted with newer parts that will require less pressure to operate. While this would cost you upfront, it will eventually save you in operating expenses down the road.

If you are using multiple compatible compressed air systems, you may be able to use some of these older parts on another system that already requires a higher amount of air pressure. Oppositely, you can also stop using high-pressure systems for low-pressure applications, which will also reduce your energy expenses.

Fix Leaks in Your Compressed Air Pipe System

Leaks are a problem in almost every compressed air system. The level at which your system leaks is what separates the most efficient compressed air systems with inefficient systems.

The average plant will lose 20-30% of their total air from leaks in their systems. This number can inflate to well over 50% if the system fails to receive any maintenance. Regularly maintaining your system is paramount to increasing your system's efficiency. Without it, you could end up paying more for wasted air than for your actual operation.

Leaks can be caused by damage or natural wear over time in your couplers, hoses, pipes, valves, and other parts of your system. If you do come across a leak in your system, you should repair it immediately. If there is even a small hole leaking out air in your system, it could end up costing you hundreds to thousands of dollars each year.

In addition to the expense, leakage can also put a lot of stress on your compressed air system. Your system will have to work much harder to produce the needed amount of pressure required for the job. This can cause other parts of your system to wear out faster, which can result in the number of leaks multiplying throughout your entire system.

Limit System Usage to Industry Applications

Another huge inefficiency presents itself when you compressed air system is used for other open blowing operations outside of your main industrial applications. Workers will carelessly use the air pressure from your system to blow away dust or keep themselves cool.

While these applications may provide a quick solution for your workers, they will prove costly in the long run. There are more efficient ways to keep workers cool or clean away debris. Just like with unintentional leaks, open blowing applications can also put a lot of unneeded stress on your compressed air system.

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