When I speak to any of our members, be they distributors, manufacturers, or even end-users, there is one topic that dominates the conversation. The rising cost of energy.  

With a 50% increase in electricity costs in the last year alone, it is impossible to ignore the financial impact. Coupled with elongated lead times for some materials and components, you might expect a bleak assessment of the market situation, particularly given the fact that compressed air and vacuum systems can be very energy intensive – often cited as consuming 10% of all the electricity used by industry.

However, the forecast is by no means negative. As BCAS members, we have a key role to play in helping our customers to mitigate for these rising costs by advising on the numerous ways that they can improve the energy performance of their equipment.  

A 50% increase in electricity costs is not welcome by anyone’s standards. But the ability to double the amount of energy saved by implementing more efficient practices should not be ignored. To put it simply, there is always an opportunity to save energy.

Simplicity is key

Compressed air and vacuum are a necessity in virtually every corner of industry. So, it makes good sense to invest wisely in these energy-consuming products to ensure they operate as efficiently as possible.

When discussing compressed air and vacuum efficiency, it is not uncommon to focus on new equipment, and how purchasing the latest technology can help to lower energy consumption. There are numerous high-efficiency compressors, vacuum pumps and ancillary equipment available on the market that can help to lower electricity consumption significantly and cut costs dramatically.

However, investing in new equipment, especially when budgets for capital investment are under scrutiny is by no means the only route available for energy savings.

Our new 10% Taskforce campaign (taskforce10.bcas.org.uk), launched in April this year, has set out to address this issue, by identifying some of the key areas where compressed air is wasted, and detailing simple steps to improve performance. And the good news is that these steps don’t always require significant cost, or time.

For example, implementing good housekeeping practices can really pay dividends. Switching off compressors when they are not in use, implementing an action plan to fix air leaks and training staff in the safe and efficient use of compressed air and vacuum can all help lower cost of ownership.

Air audits

As BCAS members, we all share a common desire to help our customers save money, and conversations will often circle back round to the ways we can help end-users invest their available budget more wisely.

Air audits provide a useful starting point, helping identify where equipment could be optimised. Often, these audits will highlight that retrofit options, such as installing heat recovery or more efficient dryer technologies, will make a lasting contribution to energy efficiency.

These typically will offer rapid payback to help lower cost of ownership further still; a key marker of success when we consider the ways we can help to minimise the cost of that initial investment.

Sustainability first

Outside of these economic pressures, environmental and social concerns are also driving end-users to improve their sustainability credentials. There is a much broader industry expectation that the compressed air or vacuum system will help address rising CO2 levels and prioritise the reduction of waste.

This is another area where our members are making an impact and helping drive change. For example, innovative compressor design is incorporating more recyclable materials into the finished product. For oil-lubricated compressors, reducing the amount of oil required results in less waste oil to dispose of.

BCAS members also have a key role to play, by encouraging their customers to implement thorough service regimes, with increasing numbers offering preventative and even predictive maintenance options.

Using the latest connectivity protocols, customers can enjoy far greater control over their machine availability and performance. And a compressed air or vacuum system that is performing as it should is offering the best possible chance to save as much energy as possible.

Standards and legislation

Aside from our role in advising customers on ways to reduce energy consumption, the Society continues to work on behalf of the industry, lobbying Government and working with other trade bodies to influence new standards and legislation.

Our work with the Department for Business, Energy, and Industrial Strategy (BEIS) continues at pace as we present the case for compressor technologies as part of the Energy Technology List (ETL).  

We support improving energy efficiency in the context of limiting the environmental impact of energy related products in the UK, but continue to discuss the broader benefits of adopting a system-based approach.  

The design and manufacture of compressors with high efficiency and long life are part of the core know-how of the industry. Over legislating may result in reducing investment in this field and the speed of improvements brought to market. We have been discussing how additional focus needs to be given to maintenance and system efficiency, in particular the area of compressed air distribution systems, to ensure that the air pressure is maintained throughout the compressed air network. 

Data sheet verification programme

Our BCAS Working Group, comprising members of the Compressor Committee representing all the major compressor manufacturers active in the UK market is continuing to work on data sheet verification programme for the UK. 

It can be problematic for businesses to compare similar technologies from different manufacturers on a true like-for-like basis, as, in the UK, there is no standard data sheet format for presenting performance data.

A similar scheme is already in operation in the US, where the Compressed Air and Gas Institute (CAGI) developed simplified test codes for 60Hz power supply compressors. 

This scheme is accepted by the US market as a fair, unbiased independent comparison tool. However, in the UK and Europe, compressors utilise a 50Hz supply, which means that performance data is not transferable; leading to the desire for a similar system to be adopted for the UK market.

In the same vein as the existing US CAGI scheme, the success of the scheme will be centered around mandatory independent third-party verification of published performance figures.  The verification programme will test a randomised sample of manufacturers’ products, within the defined range of the scheme, to ensure that manufacturer data is consistent.

In conclusion

As I near the end of my first year as BCAS president, how would I assess the market situation? It's undoubtedly challenging, but by working with a BCAS member, our customers can mitigate for many of the challenges they face.

Reducing the energy consumption of compressed air and vacuum systems need not require significant investment, but the resulting cost savings are undoubtedly worth the time and effort.  

My advice? If you’re thinking about energy performance, you need to think about BCAS. Speak to your BCAS member today and you may be surprised at some of the simple and low-cost ways you could be saving energy from your compressed air or vacuum installation. 

Mark Ranger is president at the British Compressed Air Society  

www.bcas.org.uk

Tel: 020 7935 2464