Quality Air Preparation Management

Energy analysis of compressed air production

To achieve the goal of energy-efficient compressed air generation, a reliable, specific consumption profile in line with the operating time is required. Only then can sizing and compressor run times be optimized.

This service; consists of measuring power consumption, compressed air flow, as well as pressure level and compressor load. Measurements are carried out independently of the manufacturer during operation. This monitoring document documents power and compressed air needs as well as consumption fluctuations between base load and peak load over several days. At the end you get a detailed report that clearly shows energy costs and consumption, reveals power reserves and describes your potential savings.

Your advantages:

Manufacturer-independent measurement
Measurement during operation
Transparent energy consumption of the whole system
Awareness of the output reserves of the system

Compressed air quality analysis

Compressed air quality has a direct impact on operating costs: Oil, water or particles in the compressed air consume unnecessary energy and shorten the service life of pneumatic components. This also casts doubt on process reliability and in the worst case causes sudden machine stoppage. On the other hand, an ideally sized compressed air system reduces energy costs.

This can be achieved with a professional compressed air quality measurement, where we examine centralized and decentralized compressed air preparation and determine the pressure dew point by measuring air temperature, pressure level and residual oil content. The final report gives you clear advice on how to optimize compressed air quality.

Your advantages:

Providing ideal compressed air quality
Longer service life of pneumatic components
Minimizing unexpected production disruptions
Targeted adaptation of compressed air preparation to needs

Pressure drop measurement

Compressed air distribution in the system is often neglected, a cost factor with significant savings potential that is often underestimated. By reducing the pressure by 1 bar, you can save up to 8% of energy for compressed air production. In addition, a stable pressure level is a prerequisite for reliable processes.

During pressure drop measurement, the sensors together use data loggers to simultaneously record the pressure profile at several points in the compressed air system. In this way, we detect the pressure band and determine the pressure drops. This way, you will receive accurate data and clear advice on options you can use to reduce the pressure in your system.

Your advantages:

Reducing costs through pressure reduction
Reliable processes thanks to constant pressure level

Compressed air consumption analysis

The full compressed air consumption per machine cycle is a very important parameter for evaluating the energy efficiency of machines and systems. It is also the basis for correct planning and sizing of the compressed air supply. Pressure drops due to undersizing or unnecessarily expensive oversizing should be avoided. Only actual consumption measurements can tell you how much compressed air your machines consume and how high the leak rate is.

This service consists of measuring the compressed air consumption and pressure level at standstill and during operation, as well as determining the average consumption and pressure level. You learn where compressed air is used inappropriately and what opportunities for improvement you can use.

Your advantages:

The actual compressed air consumption of stand-alone machines is determined
No unwanted pressure drop due to insufficient supply
No unnecessary energy consumption due to overfeeding
Compressed air losses due to leakage are determined
The compressed air supply to the machine can be optimally configured.

Leak detection and removal

A leaky compressed air system wastes a lot of energy and money and can compromise your process reliability. Therefore, detecting, documenting and fixing leaks in compressed air systems is an important efficiency measure.

With this service, it reviews your entire compressed air system, from the compressor to the pneumatic consumer, with an expert view; We detect leaks during operation using high-sensitivity ultrasonic detectors and classify them according to their size and cost. We also detail optimization options and a list of recommended equipment for repair in order of urgency. The report will be available to you online from the Festo Energy Savings Assessment Portal and will provide a simple and systematic way to monitor the elimination of leaks. In this way, you will be able to obtain real data on your energy losses and CO2 emissions.

Your advantages:

Leak detection is done without interrupting production
Energy and money losses as well as CO2 emissions are reported transparently
Leak detection and photos using ultrasonic detectors
Individual evaluation and classification of each leak point
Detailed list of necessary repair measures, including spare parts
Online access to the full report via the Energy Savings Assessment Portal

Machine analysis for energy efficiency

Stabilize your processes and lower your costs by strategically designing your compressed air system for the future.

During machine analysis, experienced compressed air experts measure the flow, consumption and pressure of relevant pneumatic applications, identify inefficient compressed air usage and identify opportunities for improvement. Our experts use this analysis to prepare specific recommendations, as well as to calculate the costs, savings and expected payback period of possible measures. Results and recommendations are presented to you in a detailed report. On request, we can undertake the installation/remodeling of the proposed solutions.

Your advantages:

Systematic review of the system’s pneumatic energy efficiency
Rapid identification of economically logical and technically feasible measures
Documentation of analyzed compressed air applications
On request: Installation and commissioning of developed solutions