Five overlooked compressor truths

There are many aspects of compressed air that are overlooked. A large amount is wasted. Small changes can impact your compressed air efficiency and minimize costs.


Courtesy: Samuel Zeller, UnsplashAt a recent Pressure and Profit seminar sponsored by Kaeser Compressors and held at Guaranteed Rate Field in Chicago, Kaeser Compressor business development manager Robert Glenn discussed five often overlooked truths around compressed air:

  1. Compressed air is an invisible utility
  2. Compressed air is an energy source you both generate and consume
  3. Energy as a whole is on a par with materials or labor costs
  4. Compressed air is the single largest contributor to your energy costs.
  5. According to the Department of Energy (DOE), 50% of all the compressed air you generate is wasted.

In discussing the value of better examining the actual cost of compressed air, Glenn used the example of a Tier 1 automotive manufacturer using four 1980-era compressors. The compressors needed to be manually switched on and off, producing wild variations in pressure and wasting a lot of energy in the process.

Following an air demand analysis, a variable frequency drive was added to the compressors and a master controller monitored energy use. Just those two changes produced almost $155,000 in savings, reduced maintenance costs by $19,000 and even earned the manufacturer an energy rebate from its utility.

Bob Vavra, content manager, Plant

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
Welding ergonomics, 2017 Salary Survey, and surge protection
2017 Top Plant winner, Best practices, Plant Engineering at 70, Top 10 stories of 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Setting internal automation standards
Knowing how and when to use parallel generators
PID controllers, Solar-powered SCADA, Using 80 GHz radar sensors

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me