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 efficient compressed air setup. Over the years, it had moved away from older modulating compressors to a mix of fixed-speed and variable-speed units, supported by refrigerated dryers and a pressure/flow controller. Piping was laid out in a loop to keep pressure loss low, and heat recovery was being used to displace natural gas heating. On paper, the supply side looked strong. But the company knew that expanding operations and switching to oil-free compressors also meant it was the perfect time to examine the demand side of the system.
An audit quickly revealed where the hidden costs were lurking. Using ultrasonic leak detection, 58 leaks were tagged across the plant, representing thousands of dollars in wasted compressed air. Even more costly, however, were inappropriate uses. Air motors constantly agitating ink barrels, open blowing in grinders, cracked drains, and even air-powered fans were all consuming large amounts of air that could be supplied more efficiently in other ways.
The solutions were often simple but highly effective. Ink agitators were set up to run in timed intervals instead of continuously, slashing their consumption from an estimated 70 cfm down to less than 10. Air-powered humidifiers were replaced with a high-pressure water system. Leaky drains were swapped for airless models, and fans were changed out for explosion-proof electric versions. Even compressed air ionizers in scrap collection ducts were replaced with low-air-use alternatives, saving more than 300 cfm alone.
When the new lubricant-free compressors were installed, they were paired with heat-of-compression dryers that eliminated the need for a large and constant purge flow. A central controller tied the new and old compressor rooms together, ensuring stable pressure across the entire facility.
The impact was impressive. Annual compressed air energy consumption dropped by one-third, from about 2.5 million kWh to 1.64 million! That’s the equivalent of taking an entire 200-hp compressor offline. Along with lower maintenance requirements and the ability to defer further equipment purchases, the project became a showcase for how tackling both supply and demand can deliver powerful results.
In the end, the company not only secured cleaner, oil-free air but also unlocked significant energy savings — a win for both production and the environment.
