10 Guidelines For Manufacturing With Compressed Air

By Sam Lewis

If your company uses air compression in its manufacturing process, you want to ensure it is as efficient as possible. Here are 10 principles to help make sure your compressed-air system is as efficient, cost-effective, and as safe as it can be

Be Aware Of Electrical Consumption
Avoid the misconception that the only cost of an air compressor system is the air compressor itself. The initial investment of the equipment makes a very small portion of the total cost of owning an air compressor. The energy required to produce compressed air will always be the main cost. In fact, electricity consumption makes up nearly 75 percent of the cost of owning an air-compression system.

Routine System Checkups
It is critical to know how much compressed air is being used, how much it costs, and if you are correctly using your air compressors for each manufacturing process. The best way to evaluate a compressed-air system is through logging through energy audits. Users are always encouraged to find new ways to lower their energy costs through these audits.

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What System Do Your Needs Dictate?
In some operations, a variable speed compressor is needed, but fixed speed compressors are being used. The exact opposite sentiment can also be true. Variable speed compressors only save energy if there are spikes and lulls in the demand for compressed air. Data logging will help determine if a variable speed of fixed speed machine is best for your needs.

What Are Your Air Quality Needs?
Oil-free compressors have been in demand for several years. However, before investing in this often pricey equipment, users should determine what air purity is needed in their operations. If it is determined that oil-free operations are needed, a determination of need for class one or class zero compressor should be made.

Confirm Your System Is Installed Properly
Installation is a giant component in just how efficient an air-compressor system will be. A major factor in optimizing efficiency of the system is air flow to the compressor. Air should reach the system unrestricted, cool, clean, and free of impurities. How far apart each compressor is from the next is also an important consideration. The system’s pipes should be size appropriately for air delivery, and should be bent as few times as possible.

Examine Noise Levels
A noisy system could be a malfunctioning system. Noisy systems can also negatively affect employee performance. Compressed air systems in manufacturing must meet international standards. Currently, the standard is EN ISO 2151:2008. This international regulation makes it clear-cut to verify appropriateness of a compressor for a specific environment.

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Routine Leak Checks
Leaks are easy to identify and most oftentimes easy to correct. However, in some companies, leaks cause 30 percent of generated air to be wasted. Performing a leak detection survey is cost-effective—generally less than 10 percent of the cost of the leak. These surveys should be completed annually and before any new air-compression system is installed.

Regular Maintenance
Just like a vehicle, regular maintenance in air-compression systems is the key to not only running efficiently, but also a lengthy lifespan. Avoiding routine maintenance will increase the cost of operation and can pose dangers to employees. For this reason, written plans of system analyses are a legal requirement under the Pressure Systems Safety Regulations 2000.

Safety, Safety, Safety
The air-compression system should only be used for appropriate manufacturing practices. Many workplace accidents involving compressed air occur because of horseplay or dangerous conduct — using compressed air to dust machinery, benches, and even people. Compressed air can be fatal if it penetrates the skin and enters the bloodstream. Since compressed air travels at very high speeds, should it hit an ear or an eye, it could lead to loss of hearing or blindness.

Heat Recovery
Air compressors generate plenty of heat. Heat equals energy and losing that heat means a lack of efficiency. Some systems have ways to recover heat and put it into use in other aspects of the manufacturing process, such as heating water. Some systems even allow heat generated from air compression to heat warehouse/factory space.