What is an Energy Efficient System?

An energy efficient compressed air system is one that is properly sized to your operations by being able to maintain constant and peak demand periods, while consuming as little energy as possible.

Personal Benefits of an Energy Efficient Compressed Air System

Energy & Cost Savings

An energy efficient system will consume less energy overall, leaving you with lower operating costs which means money saved! While the initial investment in these systems can be higher, the equipment quickly pays for itself through various energy savings and possible local energy incentives.

Longer Lifespans

A system that operates at optimal efficiency and receives regular maintenance will also see less wear-and-tear on internal components and receive optimal rest periods. This contributes to your system operating at its maximum lifespan, before needing to be replaced, which also saves money.

Less Downtime

With your energy efficient system receiving the proper amount of rest time and being able to meet peak demand periods, it is less likely to have an emergency shutdown or failure that can result in lost production due to downtime. An energy efficient system, properly sized to your production needs, means that it will run optimally as long as needed to complete its tasks, and have time to rest before performing the next cycle.

Quieter Environment

Most compressors that are considered energy efficient machines also provide a quieter operation. This contributes to an overall quieter work environment which can improve employee satisfaction, productivity, and safety.

Better Company Image

Operating under eco-friendly standards not only means you meet certain governmental standards, but also generates a positive brand image for your company as well. This can help attract new customers and build stronger brand loyalty towards a company that is both effective and energy efficient!

Worldwide Benefits of an Energy Efficient Compressed Air System

Reduced Carbon Footprint

If your energy efficient system is consuming less energy in your plant, that also means it is consuming less of the world’s energy! Less energy consumption also contributes to less pollution through air emissions which increases overall air quality. These energy efficient systems contribute to a reduction in your carbon footprint that help make our world a cleaner, more eco-friendly place to be!

Waste Reduction

Many industrial air compressors require lubrication of some sort to operate properly. This lubricant can come in the form of oil or a mixture of oil and water, that can contain harmful substances to living organisms thus requiring strict disposal guidelines. Many energy efficient systems also utilize condensate management systems like oil water separators that are designed to effectively and efficiently remove waste from your system and decrease the likelihood that these toxins can escape into our world. Not to mention, many energy efficient machines can also come in oil free versions that utilize technology that eliminates the risk of contamination altogether.

Consequences of an Inefficient System

The below consequences are just a few of the many consequences your system and plant may witness due to inefficient operation:

1. Pressure loss & leaks
2. Increased downtime or emergency shutdowns
3. Poor quality in end products
4. Wear and tear on internal components
5. Decreased system lifespan
6. Safety hazards within the surrounding environment
7. Louder operation
8. Inability to meet demand

How to Increase Your System’s Efficiency

Observe Output

In general, you should always be aware of how your machine operates and how much output it produces. Is it meeting your demand? Is it falling short? Is it oversized to your operations? The amount of output needed to perform tasks vs the amount of output your compressor provides should match. If it does not, this can be an indication that there is a better solution.

CFM is especially important to pay attention to. If your compressor is not producing the CFM flow that it has been rated for, there is a failure within the system that will cause severe energy inefficiencies.

Reduce Pressure Drops

An efficient system will minimize the pressure drop throughout its entire lifespan. If you are witnessing a total system pressure drop of over 10%, this is an indication that there is a problem. Installing pressure regulators can help you monitor this issue and catch problem areas quickly to be repaired or replaced.

Find & Eliminate Leaks

System leaks are a leading cause of energy inefficiency, and they can be the costliest to your system as well. Performing regular leak inspections can help mitigate this risk by confirming optimal system performance or locating leak areas to be repaired immediately. Any build up within your air piping can cause corrosion or blockage that can create leaks within your system, leading to air loss, lost production, wasted energy, and thus higher operating costs.

Install Proper Piping

To ensure your compressor is operating at its full energy efficiencies, it is imperative to have appropriate plant air piping to allow for smooth airflow throughout the facility. Air piping should NEVER be made of PVC. Also, some piping materials, like iron or steel, are prone to rust over time and cause blockages that decrease the space air has to travel through. Excessive bends and elbows within your piping will also slow the air down as it travels, which can lead to more inefficiencies.

Add an Air Receiver

Having an air receiver tank creates a “buffer zone” for your air compressor. Air receiver tanks hold pressurized air for use. On short-term, high demand periods, instead of your compressor having to work extra hard to meet this demand, your facility can pull from your air receiver that has pressurized air ready to go. This also prevents the rough, sudden start up that can be hard on your system and cause more wear-and-tear that shortens its lifespan. You can read more about how air receivers can improve your compressed air operations in our blog post: Why Adding Air Storage Tanks Is Beneficial To Your Compressed Air System.

Perform Preventative Maintenance & Maintain Parts

As with all compressed air machinery, preventative maintenance is extremely necessary in enhancing all efficiencies over time. By performing preventative maintenance, you ensure all pieces of your system are operating effectively, and if they are not, it is caught early to be repaired and prevent further damage or shutdowns. Important areas to pay attention to are the V-Belts, if loosened they can reduce the compressor efficiency so they need to maintain proper tightness, and filters, that can become clogs and cause drops in pressure.

Perform a Full System Audit

Full system audits will give you in-depth, accurate data into your compressed air operations. Performing these will give you insights to make guided decisions concerning your compressed air to save money and optimize efficiencies.

Upgrade Your Equipment

Of course, if you are utilizing old, slow, inefficient equipment, it may be time to upgrade to newer technology that utilizes energy efficient technology to meet your demands.

Energy Incentives Provided Through Zorn Partners

Zorn Compressor & Equipment works with local energy companies in both Wisconsin & Illinois to provide incentives to our customers for completing necessary energy audits, repairs, and system upgrades. Both ComEd (Illinois) and Focus on Energy (Wisconsin) have great programs to encourage manufacturers to utilize energy efficient compressed air technology, while helping them afford to do so! Reach out to Zorn today to learn more about how you can qualify for these incentives.

Energy Efficient Machines from Zorn Compressor

Zorn Compressor and Equipment has an extensive offering of energy efficient equipment ranging from air compressors to vacuum pumps to add-on equipment pieces to parts! Below is a list of a few examples of energy efficient equipment we provide from multiple top-of-the-line manufacturers:

• Variable Speed Drive Rotary & Reciprocating Air Compressors
• Variable Speed Drive Vacuum Pumps
• Cycling Refrigerated Air Dryers
• Zero Loss Air Drains

If you are looking to learn more about Zorn Compressor’s energy efficiency offerings, read our blog post: Increasing Energy Efficiency While Using Compressed Air, or contact us today!

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction. 

Our comprehensive product and service solutions keep you running 24/7.

• Reliable equipment
• Trusted brands
• Seamless, easy installation
• Post-sales support
• Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

Related Resources

• Air Compressor Cooling Systems 101
• What Is a Flow Controller & Do I Need One?
• Compressed Air Leak Detection 101
• Compressed Air Applications in Summer Outdoor Recreation
• Compressed Air Applications in Water Treatment & Wastewater Treatment
• Going Green with Variable Speed Drive Controls
• Defining Compressed Air Quality
• The Cost of Compressed Air
• Compressed Air Applications in the Glass Industry
• Traveling & Compressed Air

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