Six steps to optimise your compressed air system

2. FIND AND FIX LEAKS

One of the biggest causes of inefficiency in compressed air systems is leaks. According to Compressed Air and Gas Institute leaks should not exceed 5–10% of the system’s total air supply (although 0% is, of course, the ideal goal). In reality, many facilities lose more than 30% of their compressed air through leaks. Fixing these can increase your available air supply by up to 25%—without installing larger compressors.

3. UPGRADE TO ENERGY EFFICIENT COMPONENTS

Many older blow-off, cooling, and drying processes are inefficient and consume more air than necessary. By switching to energy-efficient compressed air products such as Super Air Knives, Super Air Nozzles and Safety Air Guns you can drastically reduce your air consumption while also lowering the noise level.

4. TURN OFF COMPRESSED AIR WHEN NOT IN USE

Compressed air left running unnecessarily is a hidden energy drain. Be sure to switch off the system, or parts of it, when machines are not in operation. This can be done in two simple ways:

• manually (e.g. ball valves) or
• automatically (e.g. solenoid valves).

Ball valves are ideal when the air flow is rarely turned off, while solenoid valves are better suited for quick, frequent shut-offs.

5. USE LOCAL COMPRESSED AIR STORAGE

Compressed air receiver tanks are a key part of many systems. They store compressed air at high pressure after drying and filtration. A secondary receiver tank, placed near the point of use, acts as a capacitor-like buffer—storing energy to handle short-term peak demands. This helps maintain stable pressure, improves overall system performance, and reduces pressure fluctuations. By sizing the tank correctly, it can deliver the necessary air volume without overloading the compressor.

6. CONTROL AIR PRESSURE

Many operators use higher pressure than necessary for blow-off applications, leading to wasted energy and increased compressor load. Reduce working pressure to the minimum required to get the job done. By installing a pressure regulator at the point of use, you can achieve significant savings—in both air consumption and energy costs. Lower pressure not only reduces costs but also extends equipment life.