By Ron Marshall The steel plant had been running its compressors at 120 psi for as long as anyone could remember. The air system was powerful and reliable, or so it seemed. But when energy costs started climbing, management called in a compressed air auditor to see if there were hidden savings. When the auditor […]
Maintaining peak compressed air efficiency
By Ron Marshall When Lisa first took over as plant engineer at a food processing facility, she inherited a compressed air system that seemed to run well enough — or so everyone thought. The compressors were tucked away in a room at the far end of the plant, and as long as production lines kept […]
12 common compressed air misconceptions
When it comes to compressed air efficiency, misunderstandings are everywhere. Many plants operate under assumptions that lead to wasted energy, higher costs, and reduced reliability. Correcting these misconceptions can improve both performance and the bottom line. Here are some of the most common myths — and the reality behind them. Compressed air is free once […]
Compressed air efficiency: The showdown at 86 psi
By Ron Marshall It all started on a Tuesday morning. Dave, a seasoned mechanic, walked onto the shop floor and felt something was off. The familiar din of the pneumatic machines sounded … weaker. He glanced at the main compressor gauge. 86 psi. For years, it had been humming along between 90 and 100. He […]
VSD compressors: Put your system on cruise control
When Dana took over as production manager at a packaging plant, she quickly learned that compressed air pressure was a constant source of frustration. Operators often complained about pressure swings, too low during peak demand and too high during quieter shifts. The compressors seemed to be either racing at full throttle or idling wastefully. Energy […]
Keeping compressed air filters efficient
By Ron Marshall Compressed air filters are often forgotten components in industrial plants, but their role is critical. They not only protect downstream equipment and processes from contaminants but also affect the efficiency of the air compressor system itself. Neglecting filters can lead to poor air quality, rising energy costs, and unnecessary wear on equipment. […]
Do your workers care about compressed air?
By Ron Marshall When Sarah took over as operations manager at a mid-sized food processing plant, she assumed compressed air was just another utility, important, but hardly worth much attention. Her team kept the machines running, and as long as production targets were met, she didn’t think twice about it. But when a compressed air […]
How an air receiver transformed a plant
When Jorge walked through the compressor room at his manufacturing plant, the big machines caught his eye, the humming compressors, the dryers, the filters. But tucked away in the corner stood a piece of equipment he hardly noticed: a tall, steel air receiver tank. It didn’t have power cables, flashing lights, or gauges that demanded […]
Show me the money: A story of hidden compressed air costs
By Ron Marshall Mark ran a busy plastics plant where compressors hummed day and night. For years, the system seemed to work just fine — air pressure was steady, production lines ran without interruption, and maintenance crews only dealt with the occasional leak. On the surface, nothing looked wrong. But as the monthly power bills […]
Air compressor failures — fix or replace?
By Ron Marshall When the main compressor at Bill’s machine shop suddenly failed, the entire plant seemed to grind to a halt. Operators stood idle, production schedules slipped, and the pressure was on to make a quick decision. Bill gathered his maintenance crew in the break room, where they weighed their options: repair the aging […]
