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## Top 7 Compressed Air Energy Saving Tips

Do you want to reduce the electricity costs associated with your compressed air system? More than likely – you can. Start by determining your annual compressed air electricity costs using this formula:

Brake Horse Power X 0.746 X Annual Operating Hours X KWH (kilowatt-hour) Cost (divided by) Motor Efficiency

*Note: 1 CFM (Cubit Feet Per Minute) @ 100 PSIG (Pound-Force Per Square Inch Gauge) for 8760 hours at an electrical cost of $110.00 per year *

Next…follow these top 7 compressed air energy saving tips:

**1. Fix your air leaks **

If you do nothing else – follow this one tip: Find and fix your compressed air leaks. Air leaks are the industries “biggest loser”!

The average plant loses 20% to 30% of its compressed air through many small air leaks. The money spent on manpower and parts to find and fix these leaks is well worth it. Note (a 1/4 inch hole will flow 103 cfm @ 100 psig)

**2. Change to a synthetic lubricant**

If you are using petroleum based lubricants, you can experience energy savings of up to 8% by switching to compressor synthetic lubricants. Plus extending equipment life and saving oil change and disposal costs.

**3. Reduce plant operating pressure **

If possible – reduce overall plant pressure. Low pressure > Low CFM usage > Low energy consumption.

Tip: Reduce plant pressure 2 pounds at a time, then test run for a minimum of 24 hours. If there is a problem with an appliance… then increase the pressure by 2 lbs until it runs smoothly again. For every 2 pounds of pressure drop – you save 1% of the electrical cost to run the air compressor.

**4. Check the differential pressure on the air compressor filters.**

Start at the compressor cabinet filter then check the compressor inlet filter.

Note: A dirty inlet filter can add up to 1% to 3% in additional electricity costs. Why? Because less air flow to the compressor inlet valve increases the compression ratio resulting in longer running time.

Next check the air/oil separator differential pressure under full load. The new separator reduces the differential pressure by about 2-3 psig. When your pressure drop reaches 8-10 psig, it’s time to change your separator elements. A waste separator element can cost you up to 5% in additional electrical costs.

Next change the control air filter element. This is an often overlooked, but still important filter where controls receive their air signal. A pressure drop here causes the controls to receive a lower pressure signal, overloading the compressor and using more electricity.

**5. Reduce compressor inlet temperature**

By lowering the inlet air temperature 10°F below 70°F, you save 2% on electricity usage. Your profit increases by up to 8% on a 30°F degree day. But increasing the inlet temperature 10°F above 70°F costs you 2% in additional electrical usage for every 10°F up to 10% at 120°F. (Inlet temperature has very little effect on lubricated screw compressors)

**6. Check differential pressure on compressed air line filters.**

Size the compressed air filter to twice (2x) your compressor CFM flow rate. This will reduce your pressure by about 2-3 psig and save 1% on energy costs. Elements will last twice (2x) longer and you will save on maintenance costs.

**7. Know what quality of compressed air your plant needs.**

Compressed air uses more energy than cleaners and dryers.

Check with the manufacturer of your equipment to determine the required air quality.

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