Air demand in an industrial compressed air system typically fluctuates. Using these patterns to reduce unloaded running hours is a first step to optimizing energy efficiency. Compressor controllers offer user-friendly ways to reduce unloaded running hours. If there are multiple compressors, then they should have been set up to do this automatically. But if there is no central controller, then the compressor pressure bands should have been set up in a cascade method, and the on-board controllers will stop the machines if they are not needed when the compressed air target pressure is achieved. Most on-board machine controllers have the function of programmable start/stop timers.
If compressors are left running unloaded after working hours, they still use as much as 25% of the energy consumed at full load. What’s more, if there are leaks in the system, the compressors may switch to loaded running occasionally, consuming even more energy.
The shorter the production time, the more that can be saved by switching off compressors instead of letting them run unloaded. If production is reduced but not stopped, a possibility would be to isolate areas of the factory that are not currently being used.
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