1. Turn It Off
There are 168 hours in a week, but most compressed air systems only run at or near full capacity between 60-100 hours. Depending on your shift pattern, turning your compressors off during the evenings and weekends could reduce your energy bills up to 20%.
2. Fix Existing Leaks
A quarter-inch air leak at 100 psi will cost you more than $2,500 a year. Pipe systems older than five years can have leaks of up to 25%. It takes energy to generate compressed air, and any air that leaks is money wasted. Approximately 80% of air leaks are not audible, so to minimize these problems, third-party help in detecting these leaks may be a necessity.
3. Conduct an Air Study (Audit)
Measure the plant air flow demand and the energy cost. This study allows you to understand the system improvement options and often provides electrical cost reduction opportunities as much as 30-75%. Often these improvements can be accomplished without significant compressed air system component replacement.
4. Reduce Pressure
Run at required pressures, not beyond. Each two psig reduction cuts energy consumption 1%. Check the system pressure and resist the urge to turn up the pressure to compensate for leaks or drops in pressure due to piping problems or clogged filters. A central supply side controller can greatly reduce the operational pressure band and orchestrate air production much more efficiently and effectively.
5. Recover Heat
Compressing air generates heat – reuse it! As much as 90% of heat can be recovered for use in your operation. For example, you can produce hot water for washrooms or direct warm air into a workspace, warehouse, loading dock, or entryway. The savings can really add up.
6. Emphasize Proper Maintenance
If you ignore maintenance, it will end up costing you more. As with most industrial machinery, a compressor runs more efficiently when properly maintained. Proper compressor maintenance cuts energy costs around 1% and helps prevent breakdowns that result in downtime and lost production. Protect your reputation and profits with proper maintenance.
Thanks to CAGI for their in depth list that we edited for our purposes.