If you are considering investing in an air compressor, running costs will be a key factor in your decision. While this depends on the type of compressor you use and the unique demand of your applications, we have provided a helpful guide to compressor running costs below.
In this article, we outline how much a fixed-speed compressor costs to run and explore the various factors that impact the price. For applications with a more varied air demand, we also cover the running costs of variable-speed compressors which may be more energy efficient.
Types of air compressors
The best air compressor depends on your application and air usage. If you use a steady amount of air, a fixed-speed compressor may be enough to run it efficiently. If your usage fluctuates, a variable-speed model is more appropriate.
What is a fixed-speed air compressor?
Fixed-speed air compressors operate at a consistent speed, with the motor running at a set RPM. Airflow is constant, regardless of demand or air pressure.
Compared to variable-speed compressors, fixed-speed compressors generally cost less upfront and can be great in the right applications. However, they are also less efficient, especially when air usage varies. In these cases, we recommend opting for a variable-speed air compressor instead.
Fixed-speed compressor costs
Initial investment
Upfront costs of fixed-speed compressors are typically lower than variable-speed models. For the PneuTech RSCR fixed-speed compressors, prices range from $724 to $884 per kW up to 135 kW models and $640 to $690 per kW for larger models. Please note that most installations also require a refrigerated dryer, filtration and air receivers.
Maintenance costs
A fixed-speed drive motor cannot optimise motor speed according to air usage, which can cause increased stress on mechanical components. This shortens the life of your compressed air system and may cause unplanned plant downtime. Combining the loss of productivity during downtime and the cost of repairs could amount to significant expenses.
Always be sure to assess your compressed air system regularly, checking for air leaks, unnecessary air use, and pressure drops in the network. These will help identify any inefficiencies in your system and alert you to problems that need fixing.
Running costs
If your air usage is consistent and unchanging, the running costs of a fixed-speed compressor will be predictable and relatively cost-effective. However, if your air usage fluctuates, the running costs will be higher than necessary and prone to flux.
To calculate running costs, conduct an assessment of your current air usage and power consumption. You can do this by determining the air usage requirements of each end-use tool that is powered by compressed air. Once you have the total air demand for all applications, you can identify the maximum air usage at any given time.
If your current fixed-speed air compressor output is higher than your total air usage, you will be spending much more on running costs than necessary. In these cases, we suggest getting a variable-speed compressor that can match supply to demand.
Example of compressor cost savings
When the Industrial Air Systems team partnered with Orams Marine, it was clear that a fixed-speed compressor would not suffice. With annual compressed air usage estimated at 4,000 hours, the Orams Marine team have projected their new variable-speed compressor to save them $23,700 every year.
What is a variable-speed drive air compressor?
If you need a versatile compressor that matches your air demand, opt for an energy-efficient variable-speed drive (VSD) compressor. Variable-speed air compressors are designed to adapt to current air demand. When demand is low, the motor slows down to reduce energy consumption. When demand increases, the motor automatically increases its speed to meet it.
Types of VSD compressors include:
Variable-speed compressor costs
Initial investment
As a general rule, the recommended trade price for PneuTech RSCR variable-speed & PM permanent magnet compressors ranges from $1,115 to $1,340 per kW up to 55 kW models and $925 to $1,090 per kW for larger models. Most installations also require a refrigerated dryer, filtration, and air receivers.
For reference, our starting prices for the PneuTech range of variable-speed compressors are as follows:
- 7.5kW Vixen model – $8,890 + GST.*
- 22kW PM variable-speed compressor – $21,390 + GST.*
*Please note that you may require additional extras, such as a refrigerated dryer, filtration, and air receivers. We call this a “plus” package.
Maintenance costs
A variable-speed drive motor optimises motor speed and compressor performance, reducing stress on mechanical and electrical components. This prolongs the life of your entire compressed air system and minimises plant downtime. If you want to reduce maintenance costs, a variable-speed compressor is the way to go.
Make sure to regularly assess your compressed air system to check for leaks, unnecessary air use, and pressure drops. This will help you to identify any inefficiencies in your system and alert you to problems that need fixing.
Running costs
A variable-speed drive motor will adjust RPM and power consumption based on current demand. Depending on the total volume of compressed air used and the variability in your operations, this could add up to hundreds or thousands of dollars in energy savings each year. In some cases, energy costs have been reduced by up to 60%.
Air compressors NZ
In summary, the running costs of your air compressor system will depend on the application, energy consumption, type of compressor, and maintenance requirements. If your current system is costing you too much, reach out to our experts for tailored advice.
If you are interested in making the switch to a variable-speed drive compressor, download a free copy of our VSD compressor brochure below. Inside, you’ll find out how to optimise your air compressor system, key machine specifications, and details on industry-leading VSD technology.
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