Compressed Air System Upgrade Cuts Costs and Boosts Efficiency
It’s easy to overlook just how much energy a compressed air system uses until the utility bills start stacking up. That’s exactly why one facility turned to Arizona Pneumatic for help. The result? A leaner, cleaner, and much more efficient system that’s saving them thousands of dollars each year.
Project Overview
Arizona Pneumatic’s compressed air system efficiency upgrade addressed key areas impacting performance: energy consumption, air quality, and environmental compliance. The project included right-sizing the compressor, leak reduction, and upgrades to air treatment and condensate management. This resulted in a more reliable, cost-effective, and environmentally responsible system.
Key Improvements
Compressor Replacement
The existing 100 HP Sullair compressor was replaced with a 50 HP Gardner Denver model. This right-sized the system to match actual demand, which immediately cut down on wasted energy and lowered operating costs.
Compressed Air Leak Detection & Repair
Arizona Pneumatic also performed a full leak detection survey and repaired leaks throughout the system. This reduced air loss by 20% and saved an estimated $12,000 per year in energy costs.
Air Treatment Upgrades
Dryer Replacement
- Replaced an undersized non-cycling dryer with a properly sized cycling air dryer built for high-ambient conditions
- Achieved consistent ISO 8573-1 Class 4 air quality year-round
- Maintained stable dew point during seasonal temperature changes
Condensate Management
- Upgraded from an outdated oil-water separator to a modern, compliant unit
- Eliminated ground contamination from lubricated condensate
- Improved safety and supported ongoing environmental compliance
Energy and Environmental Benefits
These combined improvements produced measurable results:
- Lower energy consumption and operating costs
- Enhanced compressed air system efficiency
- Stable dew point and improved air quality
- Elimination of environmental contamination risks
- Safer operating conditions and improved regulatory alignment
Recommended Ongoing Maintenance
To protect the investment and maintain system performance, Arizona Pneumatic recommends:
- Quarterly leak detection surveys
- Regular maintenance of dryers and oil-water separators
- Ongoing monitoring of system output and air quality
- Annual compressed air efficiency assessments
Want to Improve Your Compressed Air Performance?
This project demonstrates how strategic upgrades to a compressed air system, combined with proper sizing, maintenance, and leak control, can lead to major improvements in efficiency, air quality, and compliance. Arizona Pneumatic continues to help industrial clients unlock the full potential of their compressed air systems through expert design, diagnostics, and service!
Give us a call at (520) 645-8947 or visit our contact page to fill out a form and learn how an efficiency upgrade can enhance your operations.