12 Expert Strategies to Reduce Compressed Air Energy Waste

Energy efficiency in manufacturing isn’t just about cost-cutting – it's about future-proofing your operations.

At IMI, we know how vital compressed air systems are in helping you achieve these goals.  

Drawing on our internal operations and applications expertise, we’ve crafted 12 actionable strategies to help you recover a significant portion of the 30% of compressed air that’s wasted annually. 

General good practices you can implement now.

First, let’s examine some simple but effective practices that form the foundation of an efficient system.

1. Compressor service 

Ensure your compressor is serviced at the recommended intervals to maintain optimal performance.  

Regular maintenance, such as changing air and oil filters, examining belts, and checking for leaks, is vital for efficient operation and maximising the lifespan of your system. 

2. Optimise compressed air use 

Enhance efficiency by customising your air filtration to match each application’s needs.  

Use standard filtration for general-purpose machines and oil-free filtration only where necessary, such as for equipment with air bearings.  

By installing point-of-use filters where they’re actually required, rather than filtering the entire factory to the highest standard, you can cut costs, reduce energy consumption, and extend the lifespan of your equipment.  

3. Detect and fix leaks

Pay attention to any hissing sounds in your compressed air system. If you can hear a leak, you’re wasting money!

Regularly inspect your system for leaks and promptly repair any you find.

4. Zone your ring main

If you have multiple operating areas, such as manufacturing, assembly, testing, or packing, that run at different times or require different pressures, consider zoning your compressed air ring main.

This allows you to supply the correct level of air only when needed in each area rather than maintaining constant pressure throughout the entire system.

5. Correct sizing

Properly size your compressed air equipment for each application. Undersized units will struggle to meet demand and won't operate efficiently, while excessively large units are more expensive to purchase and operate.

For example, larger filters can be more efficient due to their greater surface area, which reduces pressure drop and energy use. But oversizing your filters “just in case” wastes resources. Find the right balance to ensure both efficiency and cost-effectiveness.

6. Maintain lubricators

Check that lubricators are filled with the proper oil and set to deliver the correct amount.

Too little oil can cause parts to drag and potentially burnish, while too much oil can impede efficient lubrication and, in extreme cases, lead to hydraulic lock-up. Running with empty lubricators, particularly, results in premature wear and increased costs.

Regularly checking and adjusting lubricators is essential to maintaining equipment performance and avoiding unnecessary expenses.

7. Remember: 7% per bar

If you don't need the extra pressure, turn it down! Every one-bar decrease in pressure results in roughly 7% lower energy costs for that unit. Small adjustments can accumulate significant savings over time.

Upgrade processes to boost savings

The following strategies go beyond basic maintenance and equipment optimisation, taking your energy savings to the next level. They require a little more thought and planning but can yield substantial results.

8. Optimise cylinder return strokes 

For long-stroke cylinders, you likely don’t need full system pressure on the return stroke.

Install an R82R regulator in the return line and reduce the pressure to the minimum needed for a reliable return, often around 1.5 bar. This simple change can dramatically reduce air consumption. 

9. Speed profiling for larger cylinders

For larger cylinders, consider using proportional flow valves instead of standard valves.

Proportional flow valves enable you to precisely control the air flow and speed at each point of the cylinder’s stroke, unlike standard valves that rely on fixed cushions to slow the cylinder down at the end of the stroke.

This allows you to optimise each movement, saving air and improving positioning accuracy at the end of the stroke.

10. Optimum vs maximum pressure

Pneumatic tools typically have both optimal and maximum pressure ratings. While you can connect a tool directly if your system pressure is below its maximum rating, operating above the optimal pressure wastes energy and can lead to faster wear and tear.

To avoid this, install a filter regulator or pressure regulator to reduce the pressure to the tool’s optimum level. This simple adjustment can save you 7% in running costs per bar of pressure and likely extend the tool’s lifespan.

Further eliminate wastage with Excelon® Plus

Excelon® Plus is the latest generation of IMI Norgren air preparation equipment, designed with safety, simplicity, and efficiency in mind. The range includes filters, regulators, lubricators, and filter regulators.

Here’s how you can make the most of Excelon® Plus to further reduce your energy consumption:

11. Keep filters clean

Change filter elements regularly to prevent blockages that cause pressure drops and force your compressor to work harder.

Excelon® Plus filter units have easy-to-use service kits that simplify maintenance and keep your system running efficiently.

12. Set regulators correctly

Ensure your regulators and filter regulators are adjusted to the optimal settings for your application and are locked to prevent tampering.

All Excelon® Plus regulators and filter regulators have lock-off features to maintain your energy-saving settings.

Cut out air energy waste at every stage

When implemented together, these practical activities can result in demonstrable improvements in efficiency, cost savings, and sustainability.

At IMI, we’re committed to helping you maximise these savings. Our energy-efficient products work together in concert to precisely measure, control, and optimise compressed air usage:

• The M/80 Series Flow Sensor aids in identifying minor leaks and monitoring overall system performance.

• IVAC Energy saving actuators can reduce energy consumption by up to 50% compared to conventional systems.

• Excelon® Plus offers advanced filtration, regulation, and lubrication with features like intuitive service kits and tamper-resistant designs, ensuring your system maintains peak efficiency.

By taking a proactive approach to compressed air energy management backed by the latest technology, you can unlock substantial savings and improve the sustainability of your operations – now and in the future.

To learn more about how we can help you save energy and cut costs, head here.