Is Your Compressor Costing You More Than It Should?
Discover our energy saving solutions today!
As a savvy business owner you know your business’s expenses like the back of your hand.
And whilst some costs are frustratingly fixed, some are considerably more flexible.
Now whilst some changes like energy suppliers, material costs and removing inefficient workflows come to mind quickly, what if we told you that you could be making bank by focusing on your compressed air costs?
As at J&J we want your compressor to work for you, and not the other way around. And so to help you get the most out of your machinery, we have made a handy list of our top 4 compressor efficiency tips to help you save money and energy starting from day 1.
The best way to save money with your compressor is by saving energy during its use. Simple as this sounds, this can be done in a multitude of ways but today we are going to divide this into two categories. The first category focuses on active solutions to help with a current loss of energy, and the second focuses on solutions to avoid energy waste before it happens!
So let’s get straight in!
Active Energy Loss Repair:
One of the most common reasons for wasted compressed energy is simply that the machine is not working as well as it should. From big drains like leaks, all the way to less noticeable issues like pressure drops and demand inconsistencies, the real kicker with a subpar machine is that you could be leaking money without even noticing.
Whilst regular maintenance and servicing will of course help with this, we would also recommend our steps below to ensure that you are not throwing away money simply because your machine is ineffective.
1. J&J’s Data Logger
Our first, most simple, and the most cost effective solution on our list is J&J’s data logger. It is, in fact, so cost effective that it’s actually free with your normal J&J service!
During your annual maintenance J&J actually offers a free of charge data logging service to help monitor exactly how your machine is currently working.
To do this, we simply attach our data logger during the service and leave this running for a week to gain reliable and effective data to understand your compressors behaviour.
Our technology works hard to root out any weak spots in your system including, but not limited to, demand inconsistencies, pressure drops, air and power use, and of course any potential leaks.
If these weak points are present in your compressor systems not only are you wasting energy, but you are also throwing your money away.
Because of this, if we see any issues or inefficiencies within your current machinery, J&J are there to offer the best resolution for your compressed air systems to get it back in top form in no time at all!
That means no more having undetected problems for years and definitely no more decision fatigue in deciding how to fix the issue. At J&J we can help you with both – 2 birds one stone!
And for full transparency, if your machinery is working well, we will never sell a ‘solution’ for the sake of it. At J&J we work based on data, not sales!
So all in all, this free data logging service is not only fantastic in terms of assessing your compressors current performance, and indicating any future potential issues, but also takes almost no down time in installation.
It’s a win, win.
2. A Fixed Energy Monitoring System
Now if you liked the sound of the data logger, but would like a system that tracks your data 24/7 to find leaks, inconsistencies and problems the moment they arise, then we have the solution for you!
J&J are proud to present to you (drumroll please)…. Ecoplant, the CompAir fixed data monitoring system.
Not only does this data logging system constantly monitor, analyse and adjust your pressure to give you the most efficient compressed air system possible, but it also comes with a handy dashboard so that you can measure your savings in real time.
This AI-driven brand-agnostic energy efficiency solution not only tends to cut down general running costs by up to 20%, but it also significantly lowers the overall cost of ownership.
By focusing on stable pressure, optimised energy usage and a proactive issue detective service, you can rest assured that your compressor will be consistently efficient, working perfectly, and will be saving you as much money as possible in real time.
Whilst this option does cost more than the data logging service, if constant optimisation is a deal breaker we would absolutely recommend the Ecoplant.
So, now that we have fully discussed the best methods to fix costly issues like leaks and pressure issues in real time, what about systems that will actively save you money even if your system is working well?
Enough talking, let’s get into the nitty gritty.
Preventative Energy Loss Measures:
3. A Variable Speed Drive
Now whilst this option does come with a couple of caveats, if this feature is right for you, boy is it a good way to trim the fat!
A variable speed drive, as the name suggests, will allow your compressor to control the motor speed (or RPM), electrical frequency, and power usage to match your real-time output demand. By using sensors, inverters and speed adjustments a variable speed drive prevents your motor from running at 100% all the time.
But the real pièce de résistance with the variable speed drive is that it comes with a double whammy for financial savings.
Not only are your energy costs reduced as you are only using what you need, but by encouraging stable pressure it also means less wear and tear on your motor, which means less damage and costly repairs over time!
However, as mentioned above, there are some caveats with the variable speed drive.
- It will only be beneficial if you need it. If you need your compressor to be doing identical tasks almost constantly, in reality a variable speed drive will not save you that much money or energy.
- The start up cost is significantly more expensive than a regular speed drive. Now the ROI here will really rely on your use and the size of your compressor so the efficacy of this will depend on a case by case basis.
For example, even with variable usage, applying a variable speed drive on a very small compressor used infrequently (such as at a dentist) would yield a fairly poor ROI. However, you can rest assured that at J&J we would never advise a variable speed drive for any businesses who would not yield a significant enough ROI to warrant the installation!
However, if your needs and demand do warrant a VSD, this system is a well-worn energy saving solution for a reason. Simply put, it works well and just makes sense.
4. A Heat Recovery Unit
Heat recovery units are an excellent solution to a very permanent problem.
And that problem is that SO much energy (in the form of heat) is lost during the production of compressed air.
In fact, 94% of the energy used to run your compressor converts into heat during production. And without anything to convert this heat into something useful, it sadly just lingers in the air.
Compressors of course need to be kept cool to ensure a smooth operation, and as such this excess heat has to be removed with cooling fans.
So this is the double whammy. Not only are you losing potentially lucrative hot air, but you are also paying again to get it away from your compressors!
Ok so it should now seem pretty clear that a heat recovery unit is a smart investment, but how exactly does it work?
Compressed air systems often benefit from hot process water, space heating and steam generation. Incidentally, all of these require heat to exist.
And thereby lies our solution!
By using the waste heat energy produced by the compression of air, this can then help to facilitate other processes that help in the production of the compressed air itself. And there you have your cyclical money saving solution!
If you choose to install a heat recovery unit, not only will your operating costs lower, and your C02 emissions improve, but you will typically earn back all of the money spent on the heat recovery system within a year.
Now that’s what I call a ROI!
It is also important to note here, that even with a heat recovery unit, absolutely no compressed air supply will be impacted. All gain, no pain.
At J&J we supply heat recovery units produced by CompAir and we would 100% recommend these machines due to their high quality and durability.
And, of course, if you would like to supercharge your savings by combining a variable speed drive (if applicable), the ecoplant, and a heat recovery unit, you will become a money and energy savings god!
A Brucy Bonus: On-Site Nitrogen Generation
5. Nitrogen Generation
Now, whilst this topic is not related to energy waste, when talking about saving money we simply could not avoid talking about nitrogen generation!
For example, did you know that if you are buying your nitrogen in cylinders that you are almost certainly paying too much?
As the second most widely used industrial gas in the UK (second only to compressed air), paying for nitrogen gas can be a significant cost for many businesses.
However, with the help of J&J’s nitrogen generation, you can create your own nitrogen supply on site for a fraction of the cost (per cubic metre).
In fact, by choosing to generate your own nitrogen (versus buying it in cylinder or liquid form), you could save up to 80% of the original cost.
And yes, that is from day 1 of generation!
And if that sounds good, then wait till you hear about your ROI.
In fact, most businesses will have paid back their initial installation cost within only 1-3 of owning their nitrogen generator.
And with an installation that is literally as straightforward as *pipe in compressed air, pipe out nitrogen*, if you regularly use nitrogen gas in your business then you really can’t go wrong with this money saving system!
If you would like to learn more about J&J’s on-site nitrogen generation then click here.
So there we have it!
We hope this has inspired you to make the most of your compressed air data and systems.
After all, getting to grips with your compressor doesn’t have to be a hassle, so make 2026 the year you start making those sneaky savings today.
If you would like to get more information about any of the solutions listed above then please don’t hesitate to contact our expert team today on either 0800 0278 442 or [email protected].
We can’t wait to hear from you.
J&J – When the pressure is on, we deliver.
