Why do it:

Air compressors are often one of the largest energy consumers in industrial facilities, and inefficiencies such as leaks, poor controls, or oversized units can waste huge amounts of electricity. Upgrading to efficient compressors with variable speed drives, smart sequencing, leak detection, and heat recovery systems reduces energy use and lowers maintenance costs.

Typical Savings:

• Efficient compressors (VSD, right-sizing): 20–35% reduction in energy use.

• Leak detection and repair: 10–20% savings (air leaks can account for up to 30% of losses).

• Smart controls & sequencing: 10–15% savings by matching output to demand.

• Heat recovery systems: Capture waste heat from compressors to provide hot water or space heating, delivering 50–90% recovery of input energy depending on load profile.

• Total potential: 30–60% reduction in compressor energy costs, plus additional savings on heating fuel.

• Example: A site spending £100,000 annually on compressed air could save £30,000–£60,000 per year, plus offset £5,000–£15,000 in heating costs with heat recovery.

Typical Costs:

• Rule of thumb: £700-£1,500 per kW (Motor)

• Industrial compressors (efficient/VSD models): £10,000–£30,000 each depending on capacity.

• Leak detection programme: £1,000–£3,000 annually.

• Smart controls/sequencers: £2,000–£5,000 per system.

• Heat recovery units (integrated or retrofit kits): £3,000–£10,000 per compressor.

• Installation & commissioning: £5,000–£15,000 per compressor.

• Ongoing costs: £2,000–£5,000 per year (maintenance, servicing, monitoring).