Optimizing your air compression system can significantly reduce utility bills, minimize system downtime, and extend the lifespan of your air compressor.
Energy bills are rising across the U.S., and as companies look to cut costs, they often miss the savings that come with an optimized air compressor system. Compressed air is an energyintensive resource — one of the most expensive to run — and it can account for a significant portion of a company’s energy consumption.
A methodical approach to optimizing an air compression system can yield valuable benefits in terms of energy efficiency, product quality and operational uptime. Conversely, when a system fails to function properly, it can lead to wasteful spending, damaged products, and worst of all, production breakdowns.
Justin Beckett, field technician and support specialist with ELGi, outlines a smart approach to optimizing air compression systems for energy savings. It begins with ensuring a system is properly sized and configured for the job at hand and extends all the way through to utilizing smart technologies for maximum system control.
The cost of a mismatch
Oversizing an air compression system is a common mistake. Running a larger air compressor than what is necessary results in excess energy usage. Larger units cycle on/off more frequently, drawing inrush current each time they start, causing spikes in electricity use. This cycling also causes more wear and tear on compressors, shortening their lifespan and increasing their maintenance needs.
“Everyone always thinks bigger is better — it’s not,” Beckett said. “Running a 100 hp compressor when you only need 50 hp is just doubling up on the energy required to run it. The compressor will constantly load and unload the pressure in the tank, drawing inrush currents each time it cycles. This is more expensive for the company, and it wears out the compressor much sooner.”
Running an air audit to determine the proper sizing of an air compression system is a best practice for ensuring energy efficiency and extending compressor lifespan. For a system already running, ELGi’s controller software can generate utilization metrics that show how often a compressor is cycling. If it loads/unloads more than 100 times an hour, that’s a red flag for oversizing.
It's not just the air compressor that needs to be properly sized. Air receiver tanks also need to be assessed. They store compressed air and serve as a buffer between the compressor and demand.
Insufficient tank capacity forces an air compressor to work harder and cycle more frequently.
Properly sized tanks provide more stable pressure and lower energy use.
Variable Speed Drives for smarter starts
Air compressors equipped with variable speed drives (VFDs) match airflow to demand in realtime. They ramp up and down instead of switching completely on/off. This eliminates the inrush currents that occur during cold startups, thereby reducing electricity spikes.
“It’s like when you’re driving a car. A lot of times, you’ll ease up on the gas rather than coming to a full stop,” Beckett said. “It’s easier on the system and uses less energy.”
Even when the air compressor isn’t being used for a short period — like during a shift change, cleaning period, etc. — the VFD stays on but throttles down to an idle speed rather than completely shutting off. Air compressor with VFDs work particularly well in systems with fluctuating air demands.
The power of multi-unit configurations
Some facilities opt for configurations with multiple compressors to optimize their energy usage. A setup like this would include one fixed-speed compressor and one VFD “trim” unit. The fixedspeed compressor handles the facility's steady demand, while the VFD automatically adjusts with fluctuating demand.
More advanced setups utilize three or more air compressors working together. They adjust to fluctuating demand, or they facilitate more complex production requirements.
“Multi-unit configurations help companies avoid over-reliance on a single — and often oversized — air compressor,” Beckett explained. “It also helps future-proof their systems by adding flexibility for growth or evolving production needs.”
Redundancy can also be the goal of multi-unit configurations. When one unit needs service, the other compressors take on demand. Whether it be for system outages or planned maintenance, this helps facilities avoid production downtime and keep operations running smoothly.
Smart control
Multi-unit systems are typically operated by smart master controllers that bring compressors on and offline to meet current needs. Master controllers prevent the compressors from kicking on all at once in response to a demand spike. They control timing to smooth load balance and avoid overreaction.
“Smart controllers can be programmed to select which size compressor is best for a given scenario,” Beckett said. “For example, it can scale back to a 50 hp compressor during lunch breaks instead of keeping a 100 hp unit running.”
Air compressor owners can also act smartly, of course. Many facilities leave their air compressors running overnight, even when no one is working. This cycling burns energy and shortens compressor life.
“Smart systems or simple timers work better than managing systems manually. It’s better to automate and eliminate the risk of forgetting to shut the system down,” Beckett said.
Your next move
Efficiency doesn’t just come from buying the most powerful compressor — it comes from buying the right one. A properly sized, smartly controlled system will cut energy bills and extend system life.
ELGi and its partners offer complete air audits, multi-unit strategies and the expertise to help you pull it all together.
Click here to learn more about how ELGi can help you cut energy costs with the right configuration.
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