The Challenge
A manufacturing facility operated three rotary screw compressors (22 kW, 15 kW, 7.5 kW) supplying compressed air to the entire facility. Monthly electricity consumption for the compressor system was ₹6.2 lakhs — but no one had analyzed whether this matched actual air demand.
What Became Visible
Compressor load profiling and air demand analysis revealed a massive mismatch. The three compressors were running at average 68% load factor while delivering air to a system with leakage and wastage equal to 28% of compressed air produced. Minimum system pressure was maintained at 7 bar — higher than any tool or process required. The facility was compressing air to 7 bar, losing 28% to leakage, and throttling air pressure down at tool entry points.
What Changed
Compressor control strategy changed from continuous-run to demand-based. Minimum system pressure reduced from 7 bar to 5.5 bar (matching actual tool requirements). Air system leak detection and repair program launched.
How it worked: The facility found 16 active air leaks consuming equivalent of 4.2 kW continuous. Leaks were repaired. The smallest compressor was set to variable displacement based on system demand rather than running continuously. Minimum pressure was reduced to 5.5 bar, eliminating upstream throttling. The facility reduced peak compressor load from 42 kW to 32 kW while maintaining identical air availability.
Results
peak load
of production
optimized to demand
₹14.9 lakhs annually
Compressed air systems are typically designed conservatively and operated without demand optimization. Efficiency gains from leak repair and pressure optimization are the single biggest ROI improvements in most manufacturing facilities.
Operational Reality
Most facilities lose 20–35% of compressed air energy to leakage and inefficient generation. The fixes are straightforward and have 12-month payback.