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Compressed air – a way to save money
Energooszczędność maszyn

Compressed air is one of the most common ways to power actuators in machines and production lines. Its versatility and reliability make it indispensable in many industries. Nevertheless, the compressed air preparation process is quite energyintensive, which can lead to significant operating costs. In this article, we want to show you what to look for when using this energy carrier and how you can increase its efficiency to get the most out of your compressed air while reducing your expenses and environmental impact.

How compressed air is generated

Compressed air production is a key process in many industries. Air is compressed using a variety of compressors, including piston, screw and centrifugal compressors. When air is compressed, condensation occurs, which leads to the formation of water, which accumulates in the buffer tank. Such air is not ready for direct use in the factory on the production line or in the machinery, as it contains contaminants and moisture that can negatively affect the operation of the equipment.
 
Therefore, the compressor room where the compressor is located must be equipped with additional elements to prepare the air for forwarding. These include dryers that remove excess moisture, filters that eliminate solid and oil contaminants, and condensate separators that separate and drain condensed water. Thanks to the use of these devices, the compressed air generated is properly cleaned and dried, which ensures its high quality and reliability in further production processes.

How to build a compressed air supply system

Building a compressed air supply system requires careful planning and several key elements to consider. First of all, it is necessary to choose the right compressor that will be able to deliver the required amount of compressed air at the right pressure. It is also important to take peak load into account and ensure adequate power reserves. Next, you need to install air treatment systems such as dryers and filters that will remove moisture and contaminants. It is also worth investing in buffer tanks that will store compressed air and ensure pressure stability in the system.
 
Piping and tubing should be designed to minimize pressure drops and ensure efficient airflow to all collection points. An important element is also the management and monitoring system, which will allow you to control the operating parameters of the system, such as pressure, flow and air quality. Regular maintenance and technical inspections will ensure longterm and troublefree operation of the system. Finally, it is worth noting the energy efficiency of the entire system, through the use of energy-efficient compressors and the recovery of heat generated during air compression, which can further reduce operating costs.

Air-saving opportunities – in mechanical engineering

A key way to save compressed air is to reduce the operating pressure from the 6 bar level commonly used in factories in Europe to 4 bar. An example of the effective use of this approach are Japanese companies that have been using reduced pressure in their pneumatic systems for years. Pressure relief is particularly possible and beneficial when building new production lines and machines.

Our company, during the design of devices, pays special attention to subsequent operating costs. This requires designing the pneumatic system and actuators in such a way that they can operate efficiently at reduced pressure. By using lower pressure, components selected during the design phase have a longer service life. The seals on the pistons of the cylinders wear less, and the entire air preparation system retains its functionality for longer.

Reducing the pressure not only increases the life of the components, but also significantly reduces operating costs. Lower operating pressure means less energy is used to compress air, which directly translates into cost savings and reduced CO2 emissions.

The use of a depressurization strategy in compressed air systems is therefore both economically and ecologically viable. Implementing this method when designing new production lines and machines is an investment in longterm efficiency and reliability, which is a priority in the modern approach to energy resource management in industry.

Conclusion

Compressed air is a key energy carrier in industry, but its production is energyintensive. Therefore, it is important to optimize your compressed air systems to increase efficiency and reduce operating costs. In this article, we discussed the compressed air production process, the need for treatment equipment, and the importance of proper design of power systems. We also outlined the benefits of reducing the operating pressure, which is practiced by Japanese companies. By doing this, we can significantly increase component life and save energy, which is crucial for long-term efficiency and reliability in the industry.

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