10+ Energy Saving Tips For Air Compressors For Optimal Functioning And Reduced Cost

1. Regular cleanup and maintenance of air compressors

In order to maintain the efficiency of a compressed air system, it’s crucial to prioritise cleanliness and prevent the buildup of sludge, dust, and grime. Regularly dusting the system, with specific focus on compressor coolers and heat exchangers, plays a vital role. 

To ensure proper care, you can choose between in-house maintenance by hiring qualified experts or outsourcing the services to reputable providers. Remember, regular servicing by using genuine OEM parts is essential for maintaining energy efficient air compressors. Neglecting maintenance, however, can lead to increased downtime, higher energy consumption, and expensive breakdowns.

2. Check your air compressor for leaks and fix them

To maximise energy efficiency, it’s important to check your air compressor for leaks and immediately address them. Even small leaks can have a significant impact on the overall efficiency of your compressed air system. Therefore regularly check all components, including couplings, hoses, tubes, fittings, pipe joints, quick disconnects, FRLs, valves, and flanges, for potential leaks. By actively addressing leaks and adopting energy-saving practices, you can effectively maintain the efficiency and extend the lifespan of your air compressor system. 

Moreover, buying an air compressor from a reputed provider ensures that it is of high quality, durable, and offers high efficiency. Therefore, when you’re looking to purchase air compressors for your plant, consider Bimpex, a trusted distributor known for delivering high-quality air compressors in India. 

3. Run your air compressor on optimal pressure

To maximise energy saving measures for air compressors, ensure optimal pressure while running your air compressor. A reduction of just 2 psi cuts costs by 1%. If your compressor is underperforming, check for new leaks or increased consumption. Keep in mind that higher pressure worsens leaks. Consider installing a central supply-side controller to regulate pressure effectively. 

Operating at the lowest pressure your system can handle can result in approximately 15% energy savings. For industries not requiring pressures above 100 psig, lowering header pressure saves energy.

4. Take preventive measures against pressure drops

Pressure drops in a compressed air system can cause problems over time, making it less efficient. To fix this, it’s important to deal with suspected pressure drops quickly. These drops slow things down and waste energy. 

You can minimise pressure drop by doing a few things such as redesign the system layout, replace broken hoses and tubes, check pipe connections, clean or change filters, adjust regulators, swap out lubricators, and replace after-coolers if needed. Taking these steps will make your air compressor work better and save energy in the process.

5. Turn off the air compressor for downtime

When it comes to optimising energy usage, it’s important to consider turning off the air compressor during periods of downtime. By identifying specific times when the compressor isn’t needed, such as overnight, or during scheduled maintenance breaks, you can effectively reduce energy consumption. Before shutting it down, close supply valves, release system pressure, and power it down safely following the manufacturer’s guidelines. 

It’s important to monitor pressure levels during downtime to avoid disruptions to equipment or processes. If your compressed air system has a storage receiver, you can use it to maintain a sufficient supply of compressed air without the need for continuous operation. Also, pay attention to air quality during downtime, especially if you have filtration or drying.

6. Install a supply side controller for reduced costs

A supply side controller is a device that optimises the compressed air system performance by monitoring and controlling components such as compressor, dryer and filters. This ensures that the compressed air system operates at the most energy-efficient levels by adjusting the compressor output based on the actual demand for compressed air. 

It results in energy savings, reduced wear and tear on the equipment, and lowering power consumption in air compressors. Additionally, a supply side controller can help identify and address inefficiencies in the system, further improving overall cost-effectiveness. 

7. Upgrade your compressed air piping

Upgrading your compressed air piping improves the flow, system efficiency, and saves money. Modern piping with better flow characteristics and proper sizing reduces pressure drops, ensuring efficient and smooth air delivery. It also addresses air leaks, reducing energy waste and extending the lifespan of the air compressor. 

Additionally, using corrosion-resistant materials improves air quality, preventing contamination and maintaining a clean flow. This results in improved system performance, lower operational costs, and increased overall productivity.

8. Maximise compressed air storage capacity

To optimise your air compressor system, consider increasing wet storage capacity to ensure your dryer operates at its designated flow rates. Implement dry storage and a demand controller to handle peak events, while point of use storage maintains lower header pressures for intermittent loads. While a smaller differential means less useful storage, air receivers can help maximise its efficiency. 

Additionally, explore the option of compressed air energy storage for storing energy using high-strength air-storage tanks, particularly for smaller-scale applications like air cars and air-driven locomotives.

 9. Regular maintenance of equipment like aftercooler or dryer

To ensure optimal functioning and cost savings in your air compressors, it is crucial to prioritise regular maintenance for equipment like aftercoolers and dryers. Aftercoolers play a vital role in cooling compressed air and removing moisture. It is important to maintain the aftercoolers so that they discharge air at a temperature approximately 20°F above the ambient temperature. This lower temperature reduces the moisture load on the dryer, resulting in improved efficiency.

Moreover, regular cleaning and maintenance of aftercoolers and dryers are essential to control the dew point, prevent corrosion, and minimise system contamination. By dedicating time and effort to regular maintenance practices, you can enhance energy efficiency, extend the lifespan of your equipment, and reduce overall operating expenses.

10. Check your air compressor filters and change them routinely

To ensure optimal performance and cost savings with your air compressor, it’s crucial to regularly check and change the filters. Air compressor filters are responsible for removing contaminants like dust and debris from the compressed air, preventing damage and maintaining air quality. Over time, filters can become clogged, reducing airflow and efficiency.

By routinely inspecting and replacing filters according to the manufacturer’s guidelines, you can maintain proper airflow, prevent strain on the equipment, improve energy efficiency, and avoid costly repairs. Also, after each use, turn off the air compressor, let it cool, and wipe it down for proper maintenance. 

11. Make sure you are using the right air compressor

Using the correct air compressor is essential to ensure efficient operations in various industries. Choosing a compressor that has VSD helps in saving power. For example, automotive air compressors such as reciprocating air compressors and screw air compressors are ideal for the automotive sector, where they provide reliable compressed air for various applications.

Reciprocating air compressors are also used by industries such as medical, food and beverage, textile, and pharmaceuticals, where oil-free and clean air is crucial to meet strict quality and hygiene standards. By selecting the appropriate compressor type for each industry, businesses can ensure efficient operations, meet specific requirements, and maintain product integrity. 

Are you looking for effective tips for improving air compressor energy efficiency? Our comprehensive guide on tips for extending air compressor life across industries can provide you valuable insights.