Sizing and specifying the right unit

One of the best ways to ensure plant owners and operators benefit from an optimally efficient compressor is by specifying a solution that meets their exact requirements. It is not the initial purchase price, but rather the ongoing energy costs, that will have the largest impact on the total cost of ownership – so it is vital that, before purchasing, the compressor is sized correctly and is suitable for the demands that will be placed on it.

As well as entailing a higher initial outlay, an oversized compressor will mean more expensive ongoing maintenance. The way to avoid this is by installing a performance-monitoring data-logging device. By recording important metrics such as minimum and maximum required air pressure and air flow demand, you will be better-informed when choosing a compressor.

Also remember that cheaper or less-proven units are often more prone to maintenance issues in the long term. What may at first seem like a shrewd purchase could eventually cost you more than an established, high-quality model.

The benefits of energy audits

Energy expenditure accounts for more than 80 per cent of a compressor’s whole life costs – so it is always worth undertaking a thorough and detailed energy audit. This will highlight any factors that are reducing your compressor’s efficiency, and identify opportunities to enhance productivity while safeguarding product quality and reducing site downtime.

Among the most significant causes of compressed air energy wastage are pipework leakages, which account for 35 per cent of total air consumption. It could be that shut-off valves or manual condensate valves are being left open, or that the system has leaking hoses, couplings, pipes, flanges, or pipe joints – any of which could also be letting in contaminants and potentially causing product spoilage. Alternatively, bad piping layout or aged pipework could be what is undermining your compressor’s performance.

Where heat loss is present, an energy audit may also recommend how the heat generated from a compressor could be captured and re-used. In fact, 94 per cent of compressor-generated heat is recoverable. As such, an energy recovery unit or space heating that recirculates warm air from the compressor to a local area can prove invaluable for companies looking to implement operational efficiencies.

Air management and analytics

Finally, Industry 4.0, or the Internet of Things, is enabling businesses to analyse and harness asset data in ways that have never been possible before. This offers tremendous opportunities for organisations to identify any inefficiencies in their compressed air usage, ultimately improving performance.

To meet this need, Gardner Denver has launched a new cloud-based, air management platform that delivers advanced analytics to enable you to stay in control of your installation. iConn puts a range of in-depth analytics at an operator’s fingertips, including detailed reports that track energy waste. This allows any potential issues to be remedied before they happen, leading to increased uptime and operational efficiency.

The platform particularly benefits companies with multiple remote sites or unmanned installations, as it enables users to monitor the performance of a compressor from a single location, via a mobile device, tablet, or PC. There is also no problem if sites are using compressed air products from other brands – iConn is an open platform that delivers meaningful compressed air insights to all users.