Avelair Compressed Air Solutions

Tip 3: Compressor Maintenance and Control for Optimised Efficiency

05-11-2025

Your air compressors are the heart of your compressed air system. They are also the single largest consumer of electricity within it. Even small improvements in how compressor maintenance and control can result in major energy and cost savings.

At Avelair, we often find that production teams focus on buying the right compressor but overlook how it’s operated day to day. A well-maintained, properly controlled compressor will always outperform an identical machine that is poorly set up or neglected.

The True Cost of Compressed Air

It can be surprising to learn that only around 10% of the energy used by a compressor is converted into compressed air. The remaining 90% becomes heat, which is often wasted.

Because of this inefficiency, every unnecessary running hour, every excessive pressure setting, and every delay in maintenance has a significant cost impact. Over a compressor’s lifetime, energy accounts for more than 70% of its total cost of ownership.

Optimising performance therefore isn’t just good practice, it’s essential for controlling your operational costs.

The Importance of Smart Control

Fixed Speed Compressors are most efficient when they operate at full load. When they run off-load, they can still consume between 20% and 70% of their full-load power without producing any useful air. Variable Speed Compressors are most efficient between 30 to 95% subject to their window of efficiency.

The key is to match air supply to demand as closely as possible. This is where intelligent control systems make a big difference.

Variable Speed Drive (VSD) Compressors

If your air demand varies throughout the day or week, a VSD compressor automatically adjusts its motor speed to match demand. This eliminates unnecessary off-load running and can save up to 35% in energy consumption compared with fixed-speed models.

However, not every application benefits from VSD technology. If your production runs at a constant, high demand, a fixed-speed compressor may still be more efficient. That’s why we always perform air demand analysis before making recommendations.

Sequencing Multiple Compressors

When more than one compressor is installed, a sequencer control system ensures that the right combination of machines runs at any time. It rotates usage between units, prevents them from running simultaneously at part-load, and keeps system pressure within a tight band.

This reduces energy waste and evens out wear across all compressors, extending their service life.

Control the Pressure Band

Each bar of unnecessary pressure increases energy costs by roughly 7%. Setting the system to operate within the narrowest possible pressure range saves money and reduces stress on your equipment.

Avelair’s control systems allow fine-tuned adjustment of pressure setpoints so your compressors only work as hard as needed.

Keep It Cool: Location and Ventilation

Where you place your compressors can have a major effect on efficiency. Warm intake air reduces density, meaning the compressor must work harder to deliver the same output.

For best performance:

Locate compressors in a clean, cool, and well-ventilated area.
Keep intake filters clean to maintain good airflow.
Avoid positioning the air inlet near warm air exhausts or heating systems.

A simple 4°C reduction in inlet air temperature can improve compressor efficiency by around 1% while producing drier, higher-quality air.

Planned Maintenance: The Foundation of Reliability

Skipping maintenance may seem like a short-term saving, but it always leads to higher costs later. Poorly maintained compressors draw more power, generate more heat, and are more likely to fail unexpectedly.

A planned service regime should include:

Filter changes to prevent restriction and pressure loss.
Oil and lubricant checks to ensure smooth operation.
Inspection of drains and condensate traps to prevent water build-up and leaks.
Belt and coupling checks to maintain proper alignment and reduce vibration.
Cleaning of coolers and vents to maintain safe temperatures.

At Avelair, our service engineers use genuine parts and follow OEM-approved schedules to keep your system efficient and compliant with the Pressure Systems Safety Regulations (PSSR).

Recovering Waste Heat

As mentioned earlier, most of the energy consumed by a compressor becomes heat. With proper planning, a large portion of this can be recovered and reused elsewhere in your facility.

Heat recovery systems can redirect warm air or hot water from compressors to support space heating, process heating, or hot-water systems. Depending on the configuration, this can recover 50–90% of the input energy, dramatically improving your overall site efficiency.

However, it is important to design these systems carefully. The amount of recoverable heat depends on the compressor’s duty cycle and load pattern, so professional advice is essential before investing.

Avelair can assess whether heat recovery makes sense for your site and integrate it safely with your existing HVAC or process systems – contact us on 01359 272828 or email david.wood@avelair.co.uk if this is of interest.

Why Partner with Avelair

When you choose Avelair, you’re working with a UK manufacturer that designs, installs, and supports complete compressed air systems. Our goal is to help you run your operation more efficiently, reliably, and sustainably.

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