Compressed air efficiency

Plant Efficiency

Innovative, energy-efficient compressed air systems cooperating with an individual analysis of the compressor systems imply enormous saving potentials regarding the required energy between 30 and 50 percent!

The topic of plant efficiency is the actual set screw to reduce consumption in the long term and sustainably, to reduce energy costs and at the same time to protect the environment through reduced CO2 emissions.

When buying a new compressed air system, the avoidably high purchase price is still the focus of the investment decision. However, an analysis of the full costs of a compressor operating at full capacity over its entire life cycle shows that energy costs account for by far the greater proportion of total costs, from 65 to 90 percent. A careful comparison of the performance data is therefore highly recommended.

– This is where we come in for you! –

An energy efficiency analysis by our experts will enable you to optimally adapt your system to the requirements of your company and to make the best possible use of available resources to increase the efficiency of your compressed air systems.

  • we measure the compressed air consumption of your plant over a representative period and determine the actual power consumption of your compressor.
  • we evaluate the energy efficiency of your compressed air system by comparing the energy consumption with the actual performance of your compressor.
  • based on the measurements, we analyze the efficiency of your compressor and then create an individually tailored compressed air concept for you, including the amortization period of a new compressed air system.
  • to increase the energy efficiency of your compressed air system, we design an action plan tailored to your specific needs
  • additional catalog of measures to directly increase the energy efficiency of your existing plant
We always recommend an energy efficiency analysis
  • if you want to evaluate your current compressed air system
  • if you want to replace your existing compressor with a more energy efficient one
  • if you plan new plants

Leakage locating

With unchanged productivity and otherwise the same conditions, your demand for compressed air will increase!?

The cause of this anomaly is leakage! Up to 30 % of the compressed air produced does not even reach the consumer, but is lost in the form of such leaks. Only about 20-30% of leaks are noticeable by hissing or other noises, the remaining 70% are not perceptible to the human ear and can only be localized with special technical equipment.

Based on the experience we have gained from our flow measurements, the potential savings range from 20 to 70 percent, depending on the company.

We make sure that your air does not go down the drain!

Scope of our leakage management
  • location of compressed air leaks during operation
  • detection by Sonaphone from Sonotec, records ultrasonic frequencies from 20 to 100 kHz
  • economic evaluation of all leakage points
  • detailed documentation and evaluation
Your benefits
  • you reduce your compressed air consumption by up to 30 percent
  • you reduce your energy consumption and your costs for compressed air
  • you improve your environmental balance
  • you increase the reliability of your compressed air system

Quality measurement

To ensure that machines and systems using compressed air can produce stably and reliably, certain requirements for the air used have been laid down in the ISO 8573-1:2010 standard. Accordingly, compressed air qualities were classified according to the degree of maximum permissible contamination.

Such defined cleanliness classes (dirt particles, moisture content, residual oil content) are particularly needed in industries that depend on compressed air quality that is individually tailored to their specific requirements.

Such demanding production takes place for example

  • in companies of the food industry
  • in wholesale bakeries
  • in companies of the beverage industry bakeries
  • in breweries
  • in companies of the pet food industry
  • in companies of the pharmaceutical industry
  • in companies in the chemical industry
  • in painting and coating companies

In addition, quality measurements of the compressed air provide information on the optimum design of the downstream compressed air treatment system. For a compressed air system to run smoothly, excess humidity must be removed from the system with compressed air dryers (refrigeration, adsorption or membrane dryers) and oil and dust particles must be filtered out.

CONCLUSION: The use of compressors, filters, adsorption dryers, refrigeration dryers, etc. should be carefully planned depending on the required compressed air class.

We will be pleased to advise you on the necessary measures to optimize your compressed air quality.

Scope of quality measurement
  • measurement of residual oil, pressure dew point, particles
  • measurement centralized and decentralized at defined measuring points
  • further measurements on request
  • documentation, analysis and evaluation of the measurement results
  • recommendations for action and, if necessary, optimization
  • implementation of the recommendations for action and optimization
Your benefits
  • reliable statement about the purity class according to DIN ISO 8573-1
  • identification of weak points
  • detailed report including suggestions for action and optimization
  • optimization proposals as a basis for decisions on further activities
  • documentation of data for your quality management system
  • increase in process reliability


An economical, energy-optimized compressed air supply is an important production and profit factor for your company and increases its competitiveness.

We therefore offer targeted in-house training courses to familiarize you with the relevant topics in the field of compressed air, such as

We will show you ways to save costs in the production of compressed air.

There is enormous energy saving potential in every compressed air station, e.g:

  • utilization of the compressors
  • modern compressor technologies, e.g. speed control
  • modern control systems
  • economical compressed air preparation, not too much, not too little
  • heat utilization, what "brings that"?
  • leaks: find/reduce
  • pressure losses: localize/avoid
  • correct dimensioning of components (pipelines, containers, ...)
  • and much more

There are various ways to produce oil-free compressed air economically. The seminar informs about:

  • applications of oil-free compressed air
  • classifications according to ISO 8573-1
  • possible types of oil-free compressed air generation
  • comparison of the systems (100 % oil-free compressed air systems, technically oil-free compressed air by treatment using filter systems, technically oil-free compressed air by treatment using catalyst technology)
  • possibilities of energy saving through (modern compressor technologies, e.g. speed control, modern control systems, heat utilization, what "does it do", leakages: find/reduce, pressure losses: localize/avoid, correct dimensioning of components (pipelines, containers, ...))

We are sure that the costs of compressed air supply can be effectively reduced with minimal measures.

Are you interested? Then please contact us directly.