Walk through almost any manufacturing plant and you’ll hear it, the steady hum of compressors, the hiss of air tools, the pulse of production. To many, it sounds like business as usual. But to someone who understands compressed air systems, that same sound can also mean one thing: Money leaking away! Compressed air is often […]
Air Compressors
Are you paying something for nothing? Check your compressor control!
By Ron Marshall In many industrial plants, the real cost of compressed air isn’t just the air being used on the production floor, it’s the energy consumed when the compressor is running — but not producing useful air. Choosing the wrong operating mode for your compressor can be surprisingly expensive. It’s a bit like sitting […]
The mystery of the vanishing pressure: A survival guide
Joe stood in the middle of his plant, watching a critical machine sputter to a halt. His operator pointed at the gauge, which read 25 psi lower than the compressor’s display in the back room. To fix it, Joe did what most managers do: he bumped up the discharge pressure at the source. This boosted […]
How do you achieve safety in pneumatics?
By Josh Cosford, Contributing Editor Pneumatic systems are the backbone of modern industrial automation, providing reliable and efficient power for a wide range of applications, from packaging and assembly to heavy material handling. However, the very energy that makes these systems so effective also introduces significant workplace hazards if not managed correctly. Understanding and implementing […]
Compressed air fail: Flow meter surprise
Greg had been the maintenance engineer at the manufacturing plant for nearly 10 years. He knew every pump, conveyor, and compressor in the facility. When something went wrong, people called him. But compressed air had always been a bit of a mystery. The system seemed to run fine. The compressors started, pressure stayed stable, and […]
Lower compressor energy consumption with low-cost machine adjustments
These changes can unlock plant-wide air savings, avoid major capital investment, and improve carbon footprint. By Steve Bain, Industry Segment Manager, Food and Packaging, Festo Compressed air is one of manufacturing’s largest energy expenses, and most plants run it far above what their machines actually require. By tuning machines that use excess compressed air rather than […]
Is your compressed air system out of tune?
By Ron Marshall Remember when your compressed air system was new? The compressors and dryers were shiny, the installation was perfect, and everything was finely tuned for optimal performance. But time takes its toll. Components wear out, sensors fail, and well-meaning adjustments can knock the entire system out of harmony, quietly costing you a fortune […]
How this steel plant saved thousands on compressed air
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 […]
