Think in order of value
A common sequence:
- No-cost measures: pressure setpoint, switching off unneeded machines, settings and operating practice
- Low-cost measures: leak repair, drains, filter maintenance, regulating users
- Medium-cost measures: controls, storage, piping improvements
- Larger investments: new compressors, VSD, dryers, heat recovery
How to rank
Compare each measure on cost, expected benefit, confidence in the estimate, payback and disruption. Rely on measured data, and state the assumptions behind any estimate.
Avoid overpromising
Savings depend on the plant, and they overlap: a leak repair changes the benefit of a new compressor. Calculate in an order that avoids double counting.
Verify and report
Measure after each step, compare with the baseline and update the plan. Evidence builds confidence for the next investment.
Starting data
To start, it helps to have:
- Compressor make, model, rated power and controls
- Operating pressure settings and the lowest pressure the processes need
- Operating hours and shift pattern
- Any existing power, flow or pressure records
Frequently asked questions
Where should I start?
With a baseline measurement and the low-cost measures. They often pay back quickly and clarify what is left to do.
How do I avoid double counting savings?
Order the measures and recalculate after each one, because later savings depend on earlier changes.
Can you give me a payback figure?
Only after we have measured or modelled your system. A general figure would not reflect your plant.
Field guide
Building an energy improvement plan you can fund
Compressed-air improvements range from free (fixing settings) to capital projects (new compressors or pipework). Ranking them by cost and saving lets a plant start with quick wins and fund later steps from the savings.
| Typical measure | Cost | Payback |
|---|---|---|
| Lower generation pressure, adjust controls | Very low | Immediate |
| Leak survey and repair | Low | Often months |
| Zero-loss drains, filter changes | Low | Months |
| Sequencer or master control | Medium | Depends on number of machines |
| Pipework upgrades | Medium | Depends on drop recovered |
| Heat recovery | Medium | Depends on heat use |
| New VSD or high-efficiency compressor | High | Depends on hours and current efficiency |
How to build the plan
- Measure demand, pressure profile and power for a typical week.
- List measures with estimated cost and saving.
- Do the free and low-cost measures first, then re-measure.
- Size any new equipment against the reduced demand, not the old one.
- Verify savings after each step.
What to send for a quotation
- Compressor make, model and rated power of each machine.
- Electricity tariff and annual running hours.
- Typical pressure at the compressor and at the furthest user.
- Any measurements you already have (power, flow, loaded hours).
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.