Your Air Compressor Shouldn’t Cost The Earth

The world is evolving and a focus on sustainability has never been more important.

In 2015, the United Nations’s 2030 Agenda for Sustainable Development and the 17 Sustainable Development Goals (SDG’s) set out a roadmap for ending poverty, protecting the planet and tackling inequalities.

Several of the SDG’s are relevant to the UK manufacturing sector, for the purpose of this article we will look at Goal 12 and how this relates to air compressors and compressed air systems.

Goal 12: Responsible Consumption and Production

Our planet will run out of natural resources if we don’t change the way we consume and produce. Goal 12 guides us on how to address this. The manufacturing industry can lead this by looking inwardly at how they can conserve resources during manufacture, but also by innovating and designing products that change consumer behaviour towards a sustainable lifestyle.

Key initiatives for businesses under Goal 12 include:

• Sustainable resource management: doing more with less and moving away from finite resources.
• Reducing waste:  optimising processes, finding innovative uses for by-products and shifting towards a circular economy.
• Energy efficiency: The UK has committed to be net zero by 2050. On the path to this the government sets carbon budgets, the current fourth carbon budget requires a 52% reduction in emissions by 2027, while the sixth carbon budget requires a 78% reduction by 2037. Both based on 1990 levels.
• Innovative product design: Moving away from disposable products and producing goods that are sustainable, durable and recyclable, they should have minimal environmental impact during their lifecycle.

Every component plays a part

Air compressor manufacturers invest heavily in research and development.  One key area has been motor development. The product development keeps compressor manufacturers in line with regulations, but it also means the end user benefits from significant energy savings when they come to upgrade.

Under UK regulations the vast majority of motors must conform to the IE3 standard, additionally, from July 2023 all new motors with a rated output between 75kW-200kW must meet IE4.

Many compressor manufacturers deliver motor efficiency in line with, or exceeding, IE5, which is classed as Ultra Premium Efficiency. Atlas Copco even manage to deliver this without the use of rare earth materials in their latest VSDs range.

For an end user, being aware of this can help you to achieve sustainability goals and future proof your investment in line with regulations, when upgrading your air compressor.

Understanding the energy

Over 10% of electricity supplied to industry is used to compress air. Improving energy efficiency is a key part of UN SDG 12 and crucial activity for the UK to meet the net zero by 2050 target.

For manufacturers, understanding their compressed air usage via a compressed air energy audit, is the first step to identifying where savings and efficiencies can be made.

What can manufacturers do to reduce the energy used by their compressed air system?

• Fix air leaks: one 3mm hole in your compressed air pipework could cost between £500-£900 a year, depending on your compressed air system and the pressure it runs at.
• Correctly size your equipment: when specifying compressed air equipment for your site don’t be tempted to look at the kilowatt rating and buy ‘like for like’, assess what flow (cfm) and pressure (psi) you need.
• Lower your whole system pressure: for most compressors, a reduction of 1 bar in pressure (14.5 psi) could lead to a 7% saving in electricity consumption.
• Consider a VSD compressor: a variable speed drive air compressor can deliver up to 60% energy savings compared to a fixed speed compressor.
• Focus on control: Are you sure your compressor isn’t running when not needed? Installing a controller ensures that your compressor automatically runs at its most efficient.
• Energy recovery: Approximately 70% of energy is recoverable from oil-injected screw compressors. This fits with the reducing waste part of UN SDG 12.
• Don’t forget pneumatic parts: from treating air locally to the type of valve you select or installing localised regulators – no part too small to make a difference to your energy savings.
• Pipework energy savings: it’s not just about fixing leaks, you also need to consider the design of your system, the type of pipe used, if the pipe is the correct size and whether you can zone your system.

The importance of air compressor maintenance

Air compressor maintenance plays a part in extending the lifecycle of air compressors, as well as reducing the energy used during that time.

As stated by BCAS (British Compressed Air Society), compressor output will deteriorate by more than 10% without proper maintenance. This takes into account things like:

• Changing inlet filters when necessary. Blocked filters restrict the air flow into a compressor, increasing power used by 4% and reducing efficiency (Carbon Trust data).
• Keeping coolers, radiators and ventilation grills clean and clear. A dusty site will require more frequent maintenance.
• Using OEM recommended lubricants and genuine spare parts to ensure energy efficiency and reliability.

Implementing condition-based maintenance can also help with sustainability goals through extending the lifespan of the air compressor. Condition-based maintenance focuses on monitoring specific conditions or parameters to determine when maintenance is required. For air compressors you would monitor motor performance, electrical connections, and air quality to detect early signs of potential issues.

Conclusion

There are various strategies UK manufacturers can take to ensure their air compressor doesn’t cost the earth. The UN’s Sustainable Development Goal 12, drives focus for how manufacturers and end users can significantly reduce resource consumption, energy waste and emissions.

From leveraging ultra-efficient motor technologies to conducting energy audits, optimising system designs, and implementing proper maintenance practices, each step contributes to a more sustainable future. For the UK manufacturing sector, adopting these strategies not only ensures compliance with regulations but also delivers long-term cost savings and resilience in a competitive global market.

---

FAQs: Energy Efficiency in Air Compressors

What is UN Sustainable Development Goal 12?
It promotes responsible consumption and production to conserve resources and reduce waste

Why are air compressors important for sustainability in manufacturing?
They use a significant portion of industrial electricity so optimising them saves energy and cuts emissions

What motor standards improve compressor efficiency?
IE3 is common, but IE4 and IE5 motors offer ultra-premium efficiency with lower energy use

How can manufacturers reduce compressed air energy use?
Fix leaks size equipment properly lower pressure use variable speed drives control run times and recover waste heat

Why is compressor maintenance critical?
Poor maintenance reduces efficiency by over 10% and leads to higher energy costs and downtime

What is condition-based maintenance?
Monitoring compressor health to perform maintenance only when needed, extending life and efficiency

How does system design affect energy use?
Pipe sizing, layout and zoning impact energy consumption alongside leak management

What energy savings can variable speed drive compressors provide?
Up to 60% energy savings compared to fixed speed models

How much energy can be recovered from screw compressors?
Approximately 70% of energy from oil-injected screw compressors can be recovered

Why is choosing genuine parts and lubricants important?
They maintain compressor reliability and energy efficiency over time