According to the Department of Energy, “10% of all industrial energy goes to air compressors.” Based on years of auditing, we can confirm that indeed, between 10% – 20% of all plant electricity goes to the compressor room for a typical manufacturer. That’s a massive amount of electricity most people are unaware of. Manufacturers typically purchase air compressors with price in mind, trying to find the cheapest compressor available that fits their budget. Unfortunately, discussions about how efficient that compressor is for their plant needs are usually not addressed, and that can have enormous consequences.
Over the course of 10-years, an air compressor’s energy cost can be as much as 10 times the cost to buy the compressor itself. That makes sense when you consider air compressors typically have one of the largest electric motors in a facility and usually run the most often.

10 Year Compressor Costs

Compressor Performance Comparison

Since we know that compressors consume huge amounts of electricity, we should care a great deal about how efficient it is.  The single biggest determining factor for compressor efficiency is how it’s controlled.  The primary control types for a compressor are:

  • Modulation
  • Load/Unload
  • Variable Speed Drive
  • Variable Capacity Control

Understanding how your compressor is controlled and if it’s the right for your plant’s needs will tell you whether your system is efficient or not.

At TMI, our professional experts assess compressor efficiency all the time and can provide dollar figures for what you are paying now versus what you could be paying in an improved system.