How to make compressed air systems operate more efficiently and stop costly downtime.

Compressed air is widely used in many facilities from auto shops to jet aircraft. It is a very valuable utility but can be costly, if not handled and used properly. Manufacturing facility operators consider Compressed Air as the fourth utility next to electricity, water, and gas. 

Compressed air is produced by taking air from the atmosphere and “compressing” the molecules of the air into smaller sizes and volume. These compressed air molecules are forced into a tank. More molecules into the tank mean an increase in mass, which increase density and ultimately increase pressure. That now results in compressed air! The compressor stops and shuts off when the tank is filled with pressurized air and waits until you release the air for use. Released pressurized air is a powerful energy that you can use for many pneumatic tools, equipment, and machinery.

If you are starting up a business, it is the best time to seek professional advice on the best air compressor your business will need to operate efficiently. Trained professionals can advise you whether you can easily start to operate using a portable air compressor, or an established business may need to add a standalone compressor, or save money by investing in a full feature air compressor (Air Station).  

Here are some operational pitfalls and ways on how to address them. But it is best to consult a professional. 

1. Ensure the delivery of a constant flow of steady pressure throughout your facility. However, this is a major challenge to all operators who have a periodic large demand for airflow, or for operators who have added several units of compressors through the years without properly making changes in how the air is delivered i.e. pipe size, ring main or static air line, size of connection to suit the tools requirements, etc. Consult an air compressor specialist for professional assistance.
2. If your energy cost continues to surge, it will benefit your company to consult professionals in auditing your facility to see where you are wasting energy in your compressed air production process. 
3. It is important to run your equipment at the required pressure. High pressure does not necessarily mean good performance. Unnecessary pressure wastes energy and can cause costly damage to your machinery resulting in unscheduled downtime, product loss and unforeseen service costs.
4. Leaks are major culprits for wasted energy. These are caused by unnecessarily running your system under high pressure. Keep a regular monthly check for leaks to reduce operating costs. 
5. Correcting your compressed air requirement to match your manufacturing requirement will result in energy savings, shave your operational cost significantly, and improve your facility’s impact on the environment through reduced carbon footprint. 
6. Another contributing factor to wasted energy is running your compressors 24/7 even when production volume dips. These lulls in production requirements are opportunities to save energy by turning your compressors off. It is unnecessary and inefficient to run compressors 100% when your operational energy requirement is equivalent to only 50% of the compressor’s capacity output. When this happens, 50% of the energy is immediately wasted. 

The first step in solving a problem is knowing the problem. Stop costly downtime and maximize your air compressor system. Call us, and we will visit your facility at your most convenient time.