Energy-Saving Tips for Compressed Air Systems (UK Guide)
Compressed air is one of the most expensive forms of energy in any workshop—often accounting for up to 30 % of total electricity use. The good news: most systems waste 20–40 % of that energy through leaks, poor control and inefficient equipment. This guide explains practical, low-cost steps you can take to save electricity and extend compressor life, whether you run an ABAC Genesis, Atlas Copco GX, FINI MK, NUAIR Belt-Drive or HPS Screw Compressor.
1. Fix Air Leaks Immediately
Air leaks are the number-one source of wasted energy. A single 3 mm hole at 8 bar can waste over £500 per year in electricity. Spray joints and hoses with soapy water and repair bubbling areas using proper PTFE-sealed fittings. Leak-detection kits and ultrasonic detectors pay for themselves within months.
2. Lower System Pressure
Every 1 bar reduction in working pressure saves around 7 % of power. Many systems run higher than necessary “just in case”. Adjust regulators so that tools receive only what they need. Avoid pressure drops by keeping pipework large enough and filters clean.
3. Use Automatic Drain Valves
Manually draining receivers often vents compressed air along with water. Install zero-loss automatic drain valves that discharge condensate without losing pressure.
4. Match Compressor Size to Demand
Oversized machines cycle on and off frequently, wasting energy during unload periods. Select a compressor that meets average—not peak—demand, and supplement with a smaller standby unit for spikes.
5. Fit a Variable Speed Drive (VSD)
Modern screw compressors with VSD control automatically adjust motor speed to match air consumption, typically saving 20–35 % in energy compared with fixed-speed models. Many ABAC Genesis VSD and Atlas Copco GA VSD units already include this technology.
6. Recover Waste Heat
Up to 90 % of the energy used by a compressor becomes heat. With simple ducting or a heat-recovery exchanger, you can capture this warmth to heat workshops or provide hot-water pre-heat. A 15 kW screw unit can supply enough heat to warm a medium-sized office.
7. Maintain Clean Filters and Coolers
Blocked filters and dirty coolers force the compressor to work harder. Check differential pressure monthly and replace elements when drop exceeds 0.5 bar. Blow out coolers with low-pressure air to maintain temperature below 85 °C.
8. Keep Intake Air Cool and Clean
Cool intake air increases density—every 3 °C reduction improves efficiency by ≈ 1 %. Route the intake to a shaded or exterior area away from process exhausts and dust. Fit a high-capacity intake filter and clean it regularly.
9. Optimise Receiver Tank Size
A properly sized air receiver allows the compressor to run in longer, more efficient cycles. Aim for 6–10 litres of storage per CFM of output for general use, or 20–30 litres for fluctuating demand.
10. Use Parallel Control for Multiple Compressors
When two or more compressors feed the same network, fit a sequencing controller so only the necessary units run. This prevents simultaneous load/unload cycling and balances wear across the fleet.
11. Eliminate Unnecessary Use of Compressed Air
Never use compressed air for cooling personnel or sweeping floors—it’s expensive and dangerous. Use electric blowers or vacuum systems instead. Even small habits can cut annual energy costs by hundreds of pounds.
12. Insulate and Shorten Pipe Runs
Long or poorly insulated pipes cause pressure drops and moisture build-up. Keep main lines short, looped, and appropriately sized. Use aluminium or galvanised steel rather than rubber hoses for permanent installations.
13. Schedule Preventive Maintenance
Well-maintained compressors consume less power. Follow the intervals in your maintenance guide: regular oil, filter and cooler servicing prevents pressure loss and overheating, maintaining optimal efficiency.
14. Manage Operating Hours
Switch compressors off when not in use. Fit automatic start/stop timers or pressure-based controllers so machines shut down overnight and at weekends. A 5 kW unit idling 24/7 can waste £800 per year.
15. Optimise Air Dryers and Filters
Refrigerant and desiccant dryers consume power continuously. Choose energy-saving models with cycling controls or dew-point sensors. Oversizing dryers or filters increases pressure drop—size equipment correctly for your flow and pressure.
16. Check System for Pressure Drops
Measure pressure at the compressor outlet and at the furthest tool point. If drop exceeds 0.5 bar, you’re wasting energy. Causes include undersized piping, blocked filters, or excessive quick-connect couplings—upgrade or service as needed.
17. Monitor Performance
Install a simple data-logger or smart meter to track load hours, pressure trends and energy use. Analysing this data often reveals hidden leaks, undersized receivers or poor sequencing logic.
18. Invest in Efficient Components
- High-efficiency IE3/IE4 electric motors
- Energy-saving refrigerant dryers
- Low-pressure-drop filters
- LED indicators and smart controllers
19. Train Operators
Simple training prevents bad habits—like running compressors at maximum pressure or leaving drains open. Post an energy checklist near each machine and review monthly results with staff.
20. Estimate Your Savings
Each 1 kWh saved on compressor operation reduces CO₂ emissions by roughly 0.25 kg and electricity costs by 15–20 p per hour. A 10 % efficiency improvement on a 22 kW compressor running 2 000 hours a year equates to ≈ £660 in annual savings.
Example Quick-Win Checklist
| Action | Typical Saving | Investment Level |
|---|---|---|
| Repair leaks | 5–10 % | Low |
| Reduce pressure by 1 bar | 7 % | None |
| Clean/replace filters | 2–5 % | Low |
| Add receiver tank | 3–8 % | Medium |
| Install VSD compressor | 20–35 % | High |
Safety and Compliance Note
Never compromise safety to save energy. Maintain pressure vessels and safety valves in accordance with PSSR 2000. Only qualified engineers should modify electrical or control systems.
Key Takeaways
- 🔹 Air leaks and over-pressure are the biggest energy wasters.
- 🔹 Clean filters and coolers maintain efficiency.
- 🔹 Right-sizing and VSD technology deliver long-term savings.
- 🔹 Heat recovery can offset heating bills by up to 90 % of input energy.
FAQs
Is compressed air really that expensive?
Yes – producing 1 kWh of compressed air costs roughly 8 times more than electricity used by a motor, mainly due to heat losses and inefficiencies.
Should I switch off my compressor overnight?
Absolutely. Install automatic timers or simple pressure switches so the machine shuts down when the system reaches full pressure and no demand exists.
How do I know if my system is wasting energy?
Check your compressor’s load/unload ratio. If it idles more than 40 % of the time, opportunities exist to optimise receiver size, sequencing or pressure settings.
See also: Compressed Air Dryers Explained – Refrigerant vs Desiccant