Compressed Air System Optimization Saves $44K and Cuts Energy Use in Half
A manufacturing facility came to Arizona Pneumatic with a familiar issue: their compressed air system was oversized, inefficient, and expensive to run. Air quality was unreliable, energy bills were high, and they were out of compliance with environmental standards.
They needed a fix that wouldn’t just check a few boxes. They needed a system that would cut waste, stabilize output, and lower long-term costs.
Right-Sized Industrial Air Compressors That Do the Job
The facility had been running a 100 HP Sullair compressor that was too large for what they actually needed. This led to constant cycling and energy waste. Arizona Pneumatic replaced it with a 50 HP Gardner Denver ST G2, matching output to demand.
This wasn’t just about downsizing; this was about designing a system that worked smarter, not harder.
Leak Detection That Pays for Itself
During the site audit, Arizona Pneumatic noticed leaks across the system. Once these were addressed, the leaks were cut by 20%.
This fix alone saved $12,000 every year, all without changing a single piece of production equipment.
Better Air Treatment Systems, Cleaner Results
Air quality was another issue. Their old dryer was undersized and couldn’t maintain a consistent dew point, which caused problems downstream. It was replaced with a high-ambient cycling dryer that now keeps the system within ISO 8573-1 Class 4 standards all year.
They also upgraded their oil-water separator. The old setup risked discharge violations. With the new equipment in place, this is no longer a concern.
The Impact
- Energy use dropped by 50%
- Estimated $44,000 saved each year
- Air quality is now reliable and consistent
- Environmental compliance risks were removed
- The compressor runs less often and more efficiently
What This Project Shows
Good system design isn’t about the biggest machine or the latest tech. It’s about understanding demand, spotting waste, and solving real problems. Arizona Pneumatic delivered that, without overcomplicating the solution.
You Don’t Need More Air. You Need Better Air.
Arizona Pneumatic works with manufacturers, defense contractors, medical suppliers, and other industrial teams that rely on clean, efficient air every day. We help businesses get the results they can measure with compressed air system optimization to energy-efficient equipment, and air treatment solutions.
Need to Fix Your Compressed Air System?
We’ll help you cut waste, stay in compliance, and get more life out of your equipment.
Call us at (520) 645-8947 or contact us online to get started.