Energy efficiency of compressed air
Supporting you in optimization
Compressed air is one of the most important utilities in production plants, essential for powering machines and tools.
Through management, you can reduce costs, increase process reliability, and protect the environment.
What is compressed air?
Compressed air is an energy medium created by compressing atmospheric air to higher pressure with the use of compressors. It is widely used in industry as an energy source for driving machines, pneumatic tools, and in technological processes requiring clean and dry air.
It contains the same gases as atmospheric air: nitrogen, oxygen, CO2, and other trace gases. However, during compression, the air becomes denser, increasing its density, energy, and application possibilities. To make it suitable for use, it is often treated – dried, filtered, and purified from contaminants such as oil or water particles.
Compressed air plays a key role in many industries, including automotive, food, chemical, pharmaceutical, and manufacturing plants, where it is essential for precise and reliable operation of many devices.
Main characteristics of compressed air
Compressed air has several distinctive features that make it a versatile medium used in industry. The most important are:
Multiple applications
It can be used to power machines, pneumatic tools, transport materials, or cleaning.
High availability
Air is everywhere, so compressing it requires no raw material transport.
Safety
Unlike electricity, compressed air poses no sparking risk, making it safe for explosive environments.
Simple storage
It can be stored in tanks, ensuring availability whenever needed.
Purity
Under proper conditions (in line with ISO 8573 standards), it can be used in the food and pharmaceutical industries.
Adjustability
Parameters such as pressure can be easily adjusted to specific technological process requirements.
Energy consumption
Compressing air requires significant energy input, making energy efficiency a key aspect.
What is the energy efficiency
of compressed air?
Compressed air energy efficiency focuses on maximizing the energy used for compression while minimizing losses. .
It involves actions such as:
- Regular diagnostics and system parameter monitoring.
- Leaks identification and elimination.
- Optimization of operating pressure.
- Compressors upgrades and heat recovery implementation.
- Automation and advanced control systems.
Who is this compressed air energy efficiency offer intended for?
Our compressed air energy efficiency services and solutions are designed for companies across industries that rely on compressed air in their daily processes, such as:
- Manufacturing industry – powering machines and pneumatic tools.
- Food and pharmaceutical industry – clean air in packaging and transport processes.
- Chemical and heavy industry – support in mixing, packaging, and maintenance.
- Automotive and aviation industry – precise painting, assembly, and repair.
- Energy, recycling, and waste – system control and raw material transport.
- Construction and services – operation of construction tools, car washes, and workshops.
Why is focusing on compressed air energy efficiency worthwhile?
Operating costs reduction
- Compressed air systems can account for up to 30% of total energy costs in industrial plants.
- Optimizing these systems can reduce energy losses by 20–40%, delivering tangible financial savings.
Increased processes reliability
- Efficient compressed air systems provide stable pressure and high-quality air, minimizing the risk of downtime and machine failures.
- Eliminating leaks reduces the risk of sudden performance drops that can disrupt production continuity.
Lower carbon footprint
- Energy efficiency means less energy required for air compression, which directly translates into lower CO2 emissions.
- These actions are consistent with ESG policies and can help companies meet decarbonization goals.
Compliance with legal regulations
- Optimized systems help comply with energy efficiency regulations (e.g., ISO 50001 standards).
- Effective management of compressed air energy can improve energy audit assessments and facilitate access to financial support programs for efficiency improvements.
Energy recovery
Heat generated in the compression process can be used in other processes, e.g., for heating buildings or heating process water, which allows for even greater savings.
Improved air quality
System optimization removes excess moisture, oil, and contaminants, which is essential for precise applications, such as in the food, pharmaceutical, or electronics industries.
Longer equipment lifespan
- Optimized systems operate under optimal conditions, reducing compressor load and extending their lifespan.
- Regular measurements and parameter monitoring minimize the risk of costly failures.
Increased operational efficiency
Better energy utilization allows for more efficient powering of pneumatic tools and technological processes, improving overall production efficiency.
Building competitive advantage
- Companies that focus on energy efficiency can reduce production costs and offer more competitive prices.
- Investments in modern compressed air technologies support the company’s image as innovative and environmentally responsible.
Access to new technologies
System optimization is often associated with the introduction to modern solutions such as monitoring systems, intelligent compressors, or automatic pressure management, which improve efficiency and facilitate management.
The modernization of the compressed air system is fully customized to your company’s needs ensuring smooth operation and results visible from the very first days.
Contact usBenefits of improving compressed air energy efficiency
Cost savings
Reduced energy consumption through identification and elimination of system losses.
Increased reliability
Improved air quality and stable compressed air supply.
Lower
CO2 emissions
Reduction of carbon footprint through more efficient energy use.
Better performance
Optimized compressed air systems support production continuity.
Standards and regulatory compliance
Compliance with applicable energy efficiency regulations.
Technical parameters and standards
ISO 50001
Energy management
systems
ISO 50001 relates to the development, implementation, and maintenance of an energy management system within organizations. The aim is to improve energy efficiency, reduce energy costs, and minimize the environmental impact through systematic monitoring and energy consumption management.
ISO 8573
Air purity classes for various industrial applications.
ISO 8573 defines requirements for compressed air purity, classifying it by three main parameters: solid particles, water, and oil. Compliance with this standard is essential in industries where air quality affects both production processes and equipment.
ISO 1217
Standards concerning the performance
of air compressors.
ISO 1217 defines methods for measuring air compressor performance, including capacity, power, and efficiency. This standard is key to ensuring compressor energy efficiency, which affects operational savings and the reliability of compressed air systems in various industries.
Common applications
Selected industries using compressed air in everyday operations where implementing energy efficiency brings measurable benefits:
Automotive industry – powering pneumatic tools.
Chemical industry – driving equipment and production processes.
Food industry – transporting products using compressed air.
Electronics production – quality control and cleaning of components.
And many other applications, where compressed air is a fundamental element of the technological process.
How to start?
Current system analysis
We measure energy consumption and identify key areas of loss.
Recommendations
We develop an optimization plan customized to your plant’s specific needs.
Implementation of actions
We implement changes such as sealing installations, modernizing equipment, or introducing control systems.
Monitoring
and reporting
We provide continuous support to maintain high system efficiency.
To learn more about the benefits and possibilities of improving compressed air energy efficiency, contact us today!
ContactWhy is it worth investing in the energy efficiency of compressed air?
Energy and operating cost savings: in industrial plants, compressed air can account for up to 30% of total energy costs. Without proper optimization, energy losses can reach 20–40%. By performing precise measurements and the implementation of energy management strategies, such losses can be significantly reduced, directly lowering energy bills.
Increased efficiency and process reliability: optimizing compressed air systems enables more effective management of pressure and airflow, which minimizes the risk of equipment failure. As a result, production processes become more reliable, downtime is reduced, and the plant can operate continuously and smoothly.
Environmental protection: reducing energy consumption also means lower emissions of CO2 and other greenhouse gases. Transitioning to more energy-efficient compressed air systems has, therefore, a positive environmental impact, supporting sustainability and industrial decarbonization efforts.
Better resource management and long-term savings: optimizing the compressed air system also brings long-term benefits. By monitoring consumption, identifying inefficiencies, and modernizing infrastructure, companies can not only save on energy costs but also extend equipment lifespan, thereby reducing costs for repairs and replacements.
Compliance with standards and regulations: effective management of energy and air quality does not only improve financial results but also ensures compliance with standards such as ISO 50001, ISO 8573, and ISO 1217. Compliance with these standards strengthens the company’s reputation, provides a competitive edge, and enables the acquisition of environmental and energy certifications that add value in relationships with clients and partners.
Case study: modernization of the compressed air system
At the Simoldes Plasticos factory, DB Energy engineers modernized the compressed air system by implementing a master control system. By identifying and eliminating leaks in the installation, we reduced compressed air losses, generating annual savings of over PLN 135,000.
Explore our case study