At Brammer Buck and Hickman we regularly run workshops on compressed air under the name of REHAB, which stands for:

• Reduce Energy
• Education
• Health and Safety
• Autonomous Maintenance
• Best Practise 

Here, we share our top five tips from REHAB on how to reduce energy consumption when it comes to compressed air:

Tip 1: Choose the correct components

Switching to high flow couplings could increase the productivity of air tools by some 50% and reduce energy consumption by up to 30%. In more than half of all applications, the pneumatic drive is too large for the intended purpose. Simply downsizing the cylinder or using single acting cylinders are often all that is required of a pneumatic system and can help reduce air consumption.

Also look at the connectors you are using.  Every tube run, fitting and filter causes a pressure drop.  Every 1 bar pressure drop means an increase of 7% to the cost of compressed air generation. A 90⁰ elbow can be the equivalent of a 1.6 metre pipe length.  Check to see if you can change elbows to straight connectors and Tee’s to Y pieces. 

Tip 2: Hose and tubing sizes

Opting for a tubing size with a smaller diameter for valves and cylinders can reduce air consumption, while choosing a larger diameter hose for air tools can save money. Using tubing with low drag co-efficiency can increase air flow and reduce pressure drops to optimise compressed air systems to achieve yearly savings of around £15,000. 

Tip 3: Reduce the pressure

Incorporating pressure regulators at point of use can very quickly pay dividends. Reducing the pressure by just 1 bar can see up to a 10% reduction in energy usage. Installing a regulator means the pressure may be reduced without having a negative effect on the operation of the machinery. 

Tip 4: Switch off and save

Pneumatic equipment left idling can consume between 20-70% of its full load power. Apply responsible usage principles to pneumatic components such as: installing manual shut off valves and switching off when machinery is not in use; implementing time-operated solenoid valves which allow the operation of pneumatic components only if a subsequent piece of equipment is in use; or installing sensor-operated interlocks which detect the need for compressed air equipment to operate can isolate or apply air as appropriate.

Tip 5: Stop leaks

In a pneumatic system, leakages can account for between 5-10% of the air supplied. One of the biggest sources of air leaks are push-in fittings, although it's probably the tube that’s to blame. Use a tube cutter to ensure a good seal. 

Consider installing a flow meter and invest in a Compressed Air Leak Audit to fully identify leaks so you can take remedial action.

These small adjustments are easy to make without the need for any costly equipment or intervention from third parties. In fact, they can be done by some of the most junior employees, including Apprentices, ensuring everyone can participate in the move to more sustainable processes. 

Libby Peacock is category manager – fluid power at Brammer Buck and Hickman

uk.rubix.com

Tel: 08450 510 150