As in most companies, you search for energy savings wherever you can find them. But one place you may not have looked – and where savings of up to 60% have been achieved – is in the air. Not the air all around you, but the compressed air that you almost certainly use to drive some of your equipment.
A review of older compressed air systems can quickly identify areas for improvement. In addition, optimising the system now will often reduce the need for maintenance in the future. And because you will be eliminating potential sources of failure, the general reliability of your processes and their productivity can also be expected to increase.
With decades of experience in compressed air, Festo has identified the most effective measures to help you save compressed air energy costs.
The hiss of compressed air from a leak is also the sound of money going down the drain. But although leakages can’t be 100% prevented (they’re comparable with standby electricity consumption in an electric drive system), they can be contained at an acceptable level through continual monitoring.
The main causes of leaks are human error, mechanical wear, and incorrect materials.
Most leaks are too small to be audible. Those which can be heard are generally classified as a loss rather than a leak. Howver, even a small leak wastes energy, and therefore money.
As a rule of thumb, 20% of detectable leakages in existing systems account for up to 80% of avoidable costs. The table below gives an indication of how much air is lost and what costs are incurred depending on the hole diameter.