A company producing vinyl siding was using a lower pressure blower to blow water off the product as it came out of its production machine. But the blower failed, and the staff quickly rigged up some compressed air nozzles consuming about 50 cfm. An air auditor noticed this misuse and flagged it as an inappropriate use — costing about $6,000 per year in energy costs.
Using compressed air to blow a conveyor belt clean is a common practice in industrial settings, but it comes with several significant disadvantages that often outweigh its convenience. One of the biggest drawbacks is energy inefficiency.
Compressed air is one of the most expensive utilities in a plant, requiring about 7 to 8 hp of electrical energy to produce just 1 hp of work. Blowing applications, particularly when using open pipes or unregulated nozzles, waste a tremendous amount of energy. When this method is used frequently or continuously throughout the day, the operating costs can add up quickly, especially if the system has leaks — an issue present in most facilities.
Beyond inefficiency, there are important safety concerns. Using compressed air for cleaning can be hazardous, particularly if pressures exceed OSHA’s 30 psi safety limit or if debris is blown into the air. Particles dislodged during cleaning can become airborne and pose risks to workers’ eyes, skin, or respiratory health. From a cleanliness standpoint, blowing contaminants off the belt doesn’t truly remove them — it simply redistributes them to other areas of the plant, potentially causing cross-contamination issues, especially in sensitive environments like food processing or pharmaceuticals.
There are also better alternatives available that are more efficient and effective. Mechanical scrapers, brushes, or vacuum systems can clean conveyor belts thoroughly without the high energy use or safety concerns. In cases where air flow is necessary, blower-powered air knives offer a far more energy-efficient solution than compressed air. Overall, replacing compressed air for belt cleaning is often considered low-hanging fruit for energy savings and operational improvement.
The siding company decided the high cost of the compressed air blower could easily be saved if they repaired the old low-pressure blower. Costs for the repairs were $3,000, savings that was recovered in six months.
For training in compressed air optimization: www.compressedairchallenge.org/calendar
