The following case studies provide real world examples of businesses that implemented programs that successfully reduced compressed air system use and operating costs.
Ford Van Dyke: Compressed Air Management Program Leads to Improvements that Reduce Energy Consumption at an Automotive Transmission Plant
Measures that were implemented between 2000 and 2003 have resulted in energy savings of more than 1 million kWh for compressed air, and energy and maintenance cost savings of $165,000. The total cost of planned upgrades and other measures was $336,000, yielding a 2-year simple payback.
Source: National Renewable Energy Laboratory
Raytheon: Compressed Air System Upgrade Saves Energy and Improves Performance
Raytheon Company upgraded the efficiency of their compressed air system in Andover, Massachusetts. The project included an update of the current system, the installation of more sophisticated control strategy, and an aggressive leak detection and repair campaign.
Source: National Renewable Energy Laboratory
San Jose Mercury News: Compressed Air System Upgrade Increases Efficiency and Saves Energy at a Newspaper Plant
Before the upgrade project, the San Jose Mercury News, Inc. was facing increased energy costs. Following an audit, they implemented a project that included better compressor controls, a lower leak load, more stable pressure levels, and improved air treatment. All of these added up to better performance and savings of $96,000 annually.
Source: National Renewable Energy Laboratory
Weyerhaeuser: Compressed Air System Improvement Saves Energy and Improves Production at a Sawmill
In 2000, the Weyerhaeuser Company in Oregon implemented a project at one of its facilities. After the success, it went on to implement plans at its six other facilities resulting in 6.8 million kWh and $250,000 saved annually.
Source: National Renewable Energy Laboratory
FUJIFILM Hunt Chemicals U.S.A. Achieves Compressed Air System Energy-Reduction Goals with a Three-Phased Strategy
FUJIFILM Hunt Chemicals U.S.A. performed an assessment at its Dayton, Tennessee facility to identify opportunities for improvement in its compressed air system. Following the assessment, the team implemented a plan that increased the system’s reliability, reduced system maintenance costs, reduced the facility’s overall energy use, and eliminated the use of nitrogen when compressed air systems were down.
Source: U.S. Department of Energy
The Compressed Air Leak Pilot Project was funded by a state energy grant from the Iowa Economic Development Authority. The project was completed during a six-month timeframe throughout 2014.