How to Save on Energy Costs Using a Screw Compressor

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February 17, 2022

Air Compressors are helpful for a range of applications including air filling, packaging, tools and many more applications! One possible drawback is the amount of electricity they use; air compressors can be a huge drain on energy if used inefficiently. Running your compressor for too long could allow air leaks, or using the wrong typpe of compressor can waste energy and money. Read below for some of the biggest power-wasters and how to stop or prevent them!

Six Possible Compressor Problems and How to Fix Them

1. Operating Without a Schedule

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One of the most common ways to waste energy is operating your air compressor with no set schedule. Every business works different hours and varying levels of air demands, but if the compressor is only needed for four hours out of an eight hour work day, it only makes sense that you would only want them running for four hours. Unfortunately, manually turning compressors on and off is not always possible due to time and space restrictions. Luckily, we thought about that. We carry several state-of-the-art compressor models with control panels that allow the user to set a schedule on the machine itself.

2. Leaving Leaks Unfixed

Another problem that is more common than you may think is air compressor leakage. Leaks are not always easy to detect and can contibute to wasted energy and ineffectiveness of compressors.

Depending on the usage, you could waste enormous amounts of energy over the span of a year. It is recommended to have a leak detection professional check your compressor regularly to ensure you aren't wasting energy. Duct tape is only a short term solution and will not fix the problem permanently.

3. Using Single-Stage Compressors

Single-stage air compressors are often used in HVAC applications despite their inefficient operation. They are either on or off, with no variance in power, so if you only need a little air they will turn on full blast. Variable-speed compressors are ideal to be used where possible, as they will attempt to match delivery with the air demand and not use as much power when less is required. We carry variable-speed rotary screw compressors that will save energy by operating when and how powerful you need them to be.

4. Clearing Debris

Though it is a very helpful tool, compressed air can not do everything. You could be wasting money and breaking OSHA regulations without knowing it. One of the most common misuses of compressed air is debris clearing. Unless psi is 30 or less, clearing things from the ground with compressed air is an OSHA violation. In addition, dusting debris off yourself is forbidden regardless of pressure. There are other, less expensive/dangerous ways to clean, so perhaps save the compressed air for more vital applications.

5. System Inefficiencies

Another place air could potentially be wasted is in the piping of air from the compressor to its destination. Often, processes and machinery are moved without thinking of the inefficiencies that could be created, especially if you are operating multiple compressors from a centralised location. Periodically review your piping system to make sure air is getting from the compressor to its final destination in as short a distance as possible. The further air travels, the more energy it takes, so a shorter pipeline is a great way to save energy!

6. Old Filters

One of the most helpful tips for saving energy is to change filters according to a recommended maintenance schedule. Most compressors say how often you should be replacing filters, and those schedules, based on testing and calculations, should be paid attention to! If you use filters in other parts of your facility, those should also be systematically replaced according to the schedule. Blocked filters can prevent a portion of fluid from passing through. It is extremely inefficient to operate with blocked filters which is why replacing them is a great way to save energy. All of the general maintenance items of an air compressor should also be checked regularly. Doing this will improve performance and extend the lifespan of an air compressor.

Now time to get the energy savings going!

Implementing a few of these energy savings tips could help you save thousands of dollars each year! Many operators miss many of these energy saving opportunities because they are trying to save money in the moment, but they all cost more in the long run. Fixing a leaky valve is not as expensive as all the energy is wastes. Two important things to remember; keep up with regular compressor maintenance and only turn on your air compressor when it's needed.

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