We often discuss the importance of energy audits on this blog, and for good reason. Typical savings range from 30% to 50% when the recommendations from a full system audit are put into practice. Also, the benefits of performing an audit, such as lower energy costs and higher production line efficiency, usually pay for the initial investment.
A recent article in Compressed Air Best Practices tells the story of a manufacturer that “substantially reduced its energy costs after implementing equipment, labor consolidation and procedural changes resulting from a compressed air energy audit.”
The manufacturer started with a baseline audit that ran for two weeks, monitoring the compressor’s energy usage, the cooling water pump and the dryer. They also used the audit to help determine if the company would qualify for an energy savings incentive program offered through their local electricity provider.
From the audit, the company learned that the air compressor was running at less than 25 percent capacity, but was operating at more than 70 percent power due to the compressor’s modulating controls. In addition, there were periods of high and low demand and inconsistencies in air usage from day-to-day.
To save on compressed air system energy costs, the manufacturer upgraded its equipment by installing two compressors running on a lead/lag configuration and a new air dryer. The manufacturer also reorganized employee work hours to improve production and further reduce energy consumption.
With the energy incentive and ongoing savings from implementing the energy audit recommendations, the manufacturer’s payback period was a short five months.
You can learn more about compressed air audits by reading previous posts on the topic: Frequently Asked Questions: Compressed Air System Audits and Upgrade to More Savings. Or, simply contact us or leave a comment below.
