Facility Maintenance: Reducing Compressed Air System Energy Costs (Part 2)
Rising energy prices are a major concern for many manufacturing industries, including the plastics and automotive markets. Increased energy costs are especially burdensome for small and medium sized companies, because they typically have less “wiggle room” when trying to maintain profitability against rising manufacturing costs.
As the Kalamazoo area’s leader in “green” Facility Maintenance, we are experts at identifying areas of energy waste that can be costing you thousands. And one area that is often overlooked in energy audits is compressed air.
In this two part article we show you how evaluating and optimizing the compressed air system in your facility can provide significant energy savings.
#3: Facility Maintenance: Repair Compressed Air Leaks to Reduce Energy Costs
Even if the interconnecting piping and controls are operating for maximum efficiency, air leaks can result in costly energy over-use. Facilities that do not monitor leaks typically experience a cumulative leak level equal to 30 percent or more of the total air use.
In our facility maintenance experience, implementing a formal, monitored, disciplined compressed air leak management program can almost completely reduce this 30% energy waste. What plant wouldn’t want to cut energy costs by a third?
The most effective programs are typically those that involve production supervisors and machinery operators working side by side with facility maintenance personnel. Quarterly leak inspection conducted with a high-quality ultrasonic leak locator during production and non-production should be put in place.
#4: Employ Small High Pressure Boosters
In cases where there really is a need for high pressure, consider supplying the local high-pressure need with a secondary, smaller high-pressure unit. Using a “booster” locally – rather than driving the entire system higher – can lead to substantial energy savings.
For example, if a certain press requires 100-psig minimum – but the rest of the plant runs well on 90 psig – install a booster on the high usage machine and keep the rest of the facility running at 90 psig.
Kalamazoo Area’s Best Facility Maintenance Company
As the Kalamazoo area’s leading Facility Maintenance Company, we can work with you to monitor, measure, calculate, test and reduce your compressed usage – which can dramatically reduce energy costs.
Remember, your compressed air is a very energy-intensive utility costing 8 times more than electricity. So if you are looking to reduce power costs and improve your bottom line, few areas offer as large and as immediate of a return as addressing your plant’s air compression needs.
World Class Works’ customized facility maintenance programs offer our customers energy-efficient, cost-effective, safety-conscious, turnkey maintenance services. We can maximize your efficiency, enhance production, increase quality, and improve safety & regulatory compliance – all while improving your bottom line.
We have provided world class facility maintenance services for industrial facilities across Southeastern Michigan, including Kalamazoo, Battle Creek, and St. Joseph County – as well as Kent County, Grand Rapids, Eaton County, Ingham County, Lansing, East Lansing, Sturgis, Portage, and Three Rivers.
Improve your facility’s appearance, reduce energy costs, increase worker health & safety, and extend the life of your facility and equipment, with World Class Works’ facility maintenance services. Call us today for a free facility maintenance quote.
Free Kalamazoo Facility Maintenance Quote: 888-315-2313