While traditional air compressors use considerable amounts of energy, new technology and innovation offer power savings. An energy-efficient air compressor will not only be better for your bottom line, but it may also help you meet sustainability goals.
In this article, we delve into the best ways to reduce energy consumption in your compressed air system. Additionally, we showcase various energy-efficient air compressors so you can choose the right one for your application.
Compressed air troubleshooting
When analysing the efficiency of any air compressor, the first step involves checking your system to determine if there are any efficiency problems at play. From compressed air leaks to pressure drops, there are a number of reasons why your current system may not be performing at its peak.
Compressed air leaks
It is common for large amounts of compressed air demand to disappear through leaks in the system. Monitor your system regularly and perform leak detection testing to ensure you catch any leaks, as soon as they arise.
Unnecessary air use
If you are using high-pressure air for low-pressure applications, you may need to reassess your pressure requirements. For example, it may be more economical to have a low-pressure compressor for cleaning and a high-pressure model for industrial processes.
Fluctuating air demand
Large fluctuations in air demand can cause huge pressure drops across the system. If your equipment uses air sporadically, a variable-speed drive compressor may be a wise investment.
Pressure drops in the air network
Check your system for areas prone to pressure drops. These include rust, undersized pipes, pipe constrictions, unnecessary deviations, and partly blocked filters.
How to increase air compressor efficiency
There are a number of simple and effective ways that you can increase air compressor efficiency. Below, we have compiled our expert advice for optimising your compressed air system and reducing energy consumption.
Choose the right air compressor size
Choosing a wrongly sized air compressor not only leads to wasted energy, it can also result in production issues. The best air compressor size depends on your application so ask our team for expert advice or refer to this article which outlines the best air compressors for a number of air tools.
Air receiver tank size
Air receiver tanks temporarily store air and allow everything to run consistently, increasing system efficiency. They come in various sizes, ranging from 20 litres to several thousand litres. Ensure your air receiver is sized correctly by assessing the compressor output, peak usage, airflow consistency, pressure requirements, and pipe diameter.
Regulate air pressure
Assessing your system requirements will help you to reduce the air pressure, relieving stress on equipment and lowering energy use. Check the minimum pressure requirement for each machine to run effectively and consider installing pressure regulators so your compressor will automatically meet the current demand.
Regular maintenance
Investing in regular preventative maintenance will ensure your compressor is efficient and reliable for as long as possible. It will also reduce your operational downtime and the frequency of breakdowns. Your upkeep routine should include changing filter elements and the oil, checking the condensation collection, and keeping the coils clean.
At Industrial Air Systems, our team offers preventative maintenance, spare parts, and 24/7 service on our support line. As part of our Master Maintenance Team 5-Point Pledge for Professional Service, our technician will complete your service and record all service details, parameters, and recommendations while on-site.
We also have a free compressor checklist available to download so that you can perform simple checks yourself. Regular checks of your equipment will ensure any faults are spotted before they become major issues.
Request your free compressor checklist here >>
Electric air compressors vs diesel air compressors
Diesel compressors are portable and do not require separate generators to run, making them ideal for isolated unpowered worksites. However, diesel compressors are known for being wasteful, producing greenhouse gases, and requiring more upkeep.
On the other hand, electric compressors are safer, more energy efficient, and more affordable. While they do require a power source to plug into, the benefits of electric air compressors include a smaller carbon footprint, variable speeds, low emissions, less maintenance, and high-purity air.
Oil injected vs oil-free compressors
If you currently use oil-injected air compressors that require lubrication, consider switching to oil-free scroll compressors. Since they are designed with smoother movements, the ability to switch off when not in use, and operate with fewer moving parts, scroll compressors are more efficient and require far less maintenance.
At Industrial Air Systems, we supply the PneuTech range of oil-free scroll compressors that can produce 100% pure oil-free air for any industry, without the need for inline filters.
Variable-speed vs fixed-speed compressors
The best type of air compressor will depend on your application and the quantity of air used. If your end-use requires a steady amount of air, a fixed-speed compressor is likely enough to keep it running efficiently. However, if your air usage fluctuates and requires turning on and off frequently, a variable-speed model is more appropriate.
PneuTech’s RSCRV and RSCRPM series of variable-speed rotary screw compressors are known for unparalleled performance, efficiency, and reliability. The permanent magnet screw series brings even more power-saving benefits, with cutting-edge and proven engineering processes.
Energy-efficient compressors
PneuTech Vixen Integrated Air Compressors
Combining initial capital cost, energy use, and maintenance, Vixen integrated air compressors offer the lowest lifetime costs compared to equivalent models in the industry. As the Vixen speeds up and slows down to match changing air demand, you’ll only pay for the electricity required. Some have seen electricity costs lowered by up to 60%!
Benefits include:
- VSD permanent magnet efficiency
- Low noise
- Low maintenance
- High-efficiency air-end
- Stop/start on demand
- Only runs when you need air.
The Vixen range can deliver up to 40cfm, 60cfm or 80cfm making it an energy-efficient compressed air solution for automotive repair applications or small manufacturing shops.
PneuTech Variable-Speed Drive Air Compressors
PneuTech’s RSCRV and RSCRPM series of variable-speed drive rotary screw compressors provide energy-saving efficiencies and long-term reliability. The permanent magnet (PM) series also brings power-saving benefits, with cutting-edge and proven engineering processes.
Benefits include:
- VSD permanent magnet efficiency
- Standby function
- Heavy-duty features
- Intelligent microcontroller
- Solid steel air & oil pipelines
- High-efficiency air-end and motor
- Direct-coupled.
The variable-speed range can deliver 130cfm to 840cfm making this air compressor an energy-efficient solution for industrial operations that require higher levels of compressed air to power larger tools and machinery. Plus, you’ll see the same electricity savings of up to 60%.
Which air compressor is more energy efficient?
Between the PneuTech Vixen and the variable-speed drive range, both air compressors are highly efficient and will result in energy savings of up to 60%. So if you’re looking to cut down your electricity bill or lower your power usage, either of these permanent magnet compressors could be the ideal solution. Which one you choose is up to you!
For more information and air compressor efficiency comparisons, reach out to our experts who can assess your compressed air system or download our air compressor catalogue. Inside, you’ll find specifications for all our compressors, as well as dryers, filtration, piping, and more.
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