How to Reduce Compressor Energy Cost

Compressed air is the most expensive utility in most plants — typically 10% of industrial electricity. The wins:

1. Fix leaks: 20–30% of generated air leaks out. Ultrasonic surveys pay back in months. 2. Lower setpoint: each 1 bar reduction saves about 7% energy. 3. Sequence compressors: avoid two part-loaded units when one full-loaded would do. 4. VSD on the trim unit: matches output to demand. 5. Recover heat: up to 90% of input energy comes back as usable hot air or water.