Compressed air is one the most important industrial energy sources. In Germany alone, some 62,000 pneumatic installations are in operation. Not infrequently, however, these installations do not include any monitoring facilities – a serious error, since 79% of the costs of compressed air are accounted for by the electricity used for generation and preparation. Even if compressors, distribution systems and pneumatic actuators are correctly dimensioned, leakage often causes losses of up to 600 l/min. What does it matter, it’s only air, users might think. But even a reduction of compressed-air losses of 100 l/min. saves up to 1000 euros a year.

However, users often fail to exploit this potential for savings due to lack of know-how. Furthermore, in many cases the technical equipment necessary to localise losses is not available. Frequently, lack of time and clarity regarding operational responsibilities prevent the implementation of energy-saving measures. This is precisely where that Festo Energy Saving Services come into play. They can help to monitor and optimise compressed air consumption by simple means. These services always begin with a report thoroughly describing the actual situation and an analysis of the complete pneumatic installation in question in order to identify all the weaknesses, from the compressor through to the applications.


Reducing energy costs
With optimum leak management, costs drivers have no chance of escaping detection. Each leakage point which is eliminated has an immediate effect in reducing compressed-air costs. According to a study by the Fraunhofer Institute ISI (“Compressed Air Systems in the European Union”, 2000), the elimination of leaks alone enables around 42% of total potential savings to be achieved. As part of an efficient leak-management system, a specialist will use an ultrasound detector to check the compressed air system for leaks and will record each leak together with all the associated technical data, such as details of the spare parts required. This documentation will then serve as a master plan for possible savings. This will show all the required maintenance measures and lists the long-term savings against the short-term repair costs.