When choosing a car, consumers rely on fuel economy ratings to compare efficiency. Miles per gallon or liters per 100 kilometers allow buyers to understand how far a vehicle can travel with a given amount of fuel. This standard measure is an essential tool for making informed purchasing decisions. Compressed air systems have a similar […]
Unlocking compressed air efficiency in the plastics industry
By Ron Marshall In plastics manufacturing, compressed air is as essential as the raw material itself. Whether it’s blow molding bottles or supporting injection molding machines, compressed air drives productivity. But it also represents one of the largest opportunities for efficiency gains — especially when system design and operation push pressure higher than necessary. One […]
The “dirty thirty” — Why the last few feet of piping matter
When people talk about improving compressed air systems, the focus is usually on compressors, dryers, filters, and main piping. But there’s a part of the system that often gets overlooked — the last 30 feet of piping that connects your machine to the main header. In the industry, some folks call this stretch the “dirty […]
How can you cut energy waste with smarter compressed air management?
A plastics product company recently proved how much can be gained by taking a fresh look at compressed air systems. What began as a move toward lubricant-free compressed air for product quality quickly became an opportunity to improve efficiency, reduce waste, and cut energy costs in a big way. The facility already had a fairly […]
A plant manager’s mission: Making compressed air more efficient
A plant manager had been running the same manufacturing facility for nearly a decade, but compressed air had always remained a bit of a mystery. It was essential to the operation, yet notoriously expensive. He knew the compressors were energy hogs, and he was tired of watching electricity costs climb year after year. Determined to […]
How do compressor cycle times impact efficiency?
By Ron Marshall Robert, the plant manager, was puzzled. His compressed air system had been running smoothly, but his energy bills seemed high. After reviewing his equipment, he realized the issue was the compressor’s cycle time. In a typical compressed air system, a lubricated screw compressor operates in load/unload mode. The cycle time refers to […]
How a plant manager solved his overheating problem
Chuck, a seasoned plant manager, was used to solving problems. But this summer, his compressed air system was giving him a run for his money. Temperatures in the compressor room were soaring. Alarms were sounding. One of the rotary screw compressors had already shut down twice due to high temperature. Production was stalling, tools were […]
Unlocking efficiency with compressed air system analysis
Compressed air is one of the most expensive utilities in an industrial facility — yet many operators don’t fully understand its cost or efficiency potential. That’s where a compressed air system analysis can make a powerful difference. Whether conducted by a utility, manufacturer, or independent consultant, a well-executed analysis can uncover hidden inefficiencies and chart […]
Why do your compressors keep running — even after you’ve fixed the demand side?
By Ron Marshall You’ve sealed leaks, upgraded nozzles, optimized piping, and trained your team on compressed air efficiency — yet all your compressors are still running. Sound familiar? You’re not alone. Many facilities invest heavily in improving the demand side of their compressed air system, only to see little or no reduction in compressor usage. […]
Why your compressed air system may be costing more than you think
By Ron Marshall If you’ve ever heard that it takes between 7 and 8 hp of input energy to get just 1 hp of work from a compressed air system, you might already suspect that these systems aren’t the most efficient. But the reality is even worse. In real-world industrial settings, compressed air systems often […]
