How to reduce the cost of compressed air

Compressed air is one of the five forms of motive power along with electricity, water, gas and steam. In pharma manufacturing facilities, it is often used as an energy source despite it being relatively costly, much like steam. Allen Cockfield, CEO of Artic Driers, discusses how to dramatically reduce the cost of compressed air while increasing bottom-line profits by focusing on efficiencies.

Knowledge equals success. COVID-19 has wrecked many companies’ profits; some are now borderline operations. With air compressors and air dryers being large consumers of energy in many companies, it pays to keep tight control of a compressor station’s power costs and the air quality that it delivers.

Attention should be given to compressed air efficiency within the plant. Every part of a plant needs to operate at the peak of its efficiency levels. This leads to a more sustainable operation.

A health check

Compressor performance testing is now available. Artic Driers’ portable S110 Power Meter benchmarks the air flow performance of an air compressor versus its power consumption per cubic metre.

This data can be compared against CAGI (Compressed Air & Gas Institute) test results, or the supplier’s data sheet. The information can also be used to determine if a compressor should be overhauled as it’s proof of a compressor’s health status.

Air leak detection

Air leaks are quickly identified with the use of an ultrasonic leak detector. With compressed air costing around ≥R0.13 per m³, the loss of compressed air to leaks alone can cost a company hundreds of thousands a year.

A 160kW air compressor with a simple service plan when running 24/7/365, will cost up to R1.5m per annum to operate. A 20% leak loss will likely cost R300 000 per year.

The costs of leak losses can easily be avoided with ultrasonic leak detection and flow meters, which quickly identify leaks. The S531 ultrasonic leak gun locates the leak, grades the severity, provides an accurate cost of the leak and the volume of air. It even writes a management report.

It is essential to overall efficiency that air leakage in the distribution system does not bleed bottom-line profits.

Compressed air quality

Poor quality compressed air will inevitably mean that production will be affected. The efficiency of robotics and pneumatics will suffer. Automation systems will be impaired and equipment life cycles will be shortened.

Unplanned outages will also be the norm with poor quality compressed air. Therefore, appropriate compressed air quality is essential to avoid these outages. Compressed air contamination increases compressed air wastage as drain traps and drain legs are left open to purge water and oils from the compressed air distribution system.

Efficiency, minimising waste, reducing downtime and stopping unplanned outages are all key to reducing the cost of compressed air while ensuring long-term company sustainability and increased profitability.

Did you know?

Artic Driers has the ability to test compressed air quality inline with ISO 8573 standards, using portable or fixed-base station equipment. The company also provides compressed air leak audits and dew point and flow tests.

10 tips for a more efficient system

1. Use a suitable air dryer and filtration system to remove water, oils and other contaminants from the air lines.

2. If a twin-tower heatless pressure swing dryer is used, fit a dewpoint controller to reduce purge air wastage.

3. Don’t run compressors at a higher pressure than necessary – it’s a power waster.

4. Design the ring main with a view of long-term expansion, minimal corrosion, system condensate drainage and low pressure drops.

5. Reduce air line pressure drops, ensure distribution lines are rings mains and that they are big enough for the flow rates.

6. Fit inline filters sparingly as they can cause pressure drops; rather concentrate on decontamination in the compressor room.

7. Ensure air speeds are kept low as this reduces pressure drops.

8. Perform air leak audits every three months.

9. Benchmark production lines with air flow meters to ensure proper use of compressed air.

10. Eliminate the improper use of compressed air.

Locally-produced air dryers

Artic Driers is a family-owned and operated company with a 30-year history in the compressed air treatment industry. The company represents a broad range of OEM suppliers and operates from a spacious distribution and manufacturing base situated near OR Tambo International Airport.

With stocks exceeding R4.1m, every effort is made to maintain consistent supplies in a world that has been turned upside down by COVID-19 and civil unrest.

To provide faster turnaround times and increase local employment, Artic Driers now produces the Sahara Series of air dryers in South Africa. This comprehensive range of heatless pressure swing air dryers are cost-effective and built tough for use in the most demanding environments throughout Africa.