Heiko Fleischhacker: Energy efficiency is crucial for the competitiveness and sustainability of any company. However, when looking at the compressed air system, I always notice that the focus is often only on power consumption. Many companies already rely on energy-efficient lighting or photovoltaics – but the potential in the compressed air system is often overlooked.
They usually limit their consideration of energy efficiency in compressed air to the compressors. Discussions about high costs often focus on compressed air generation. The entire compressed air system – from the generation to the use of compressed air – must be analyzed. This partial view means that valuable savings potential remains untapped.
Heiko Fleischhacker: Producing, distributing and processing compressed air in an energy-efficient way is complex. Although many customers are specialists in their own production processes, they have only limited knowledge of the compressed air systems they use. In my experience as an auditor, many customers do not know which setting screws they need to adjust in which order to achieve a sustainable increase in efficiency. Energy management officers and maintenance technicians often lack the necessary expert knowledge in pneumatics. Compressed air optimization goes far beyond eliminating leaks. It requires broad technological expertise and a holistic understanding of the compressed air system – from the compressor station to the pneumatic application. An example: A few weeks ago, I carried out an audit at an established pharmaceutical company. A particularly high quality of compressed air was produced there. However, no one ever questioned whether this was actually necessary for the production process. By making a small adjustment to the compressed air quality, we have achieved particularly rapid and sustainable energy savings. This makes it clear once again that a comprehensive consideration of the compressed air system, the compressed air requirements, and an in-depth understanding of pneumatics are essential.
Heiko Fleischhacker: A compressed air energy efficiency audit is a holistic assessment of a company's compressed air system – from the compressor room to the pneumatic application. The aim is to identify inefficient areas and opportunities to save energy. This should reduce costs and CO₂ emissions, which will increase productivity and improve sustainability. The audit provides a company with valuable insights and answers in several key areas. It transparently shows how efficiently the compressed air is generated, how well the company's own compressors are utilized, and how effectively the compressed air is routed through the system. This identifies potential for improvement in the infrastructure.
At the same time, the audit provides important information about the compressed air quality. This is crucial for meeting production requirements and ensuring reliable machine performance. The audit also shows how efficiently the compressed air is used in the various applications. At the end, the companies receive a detailed report with precise data and prioritized recommendations for action that can be used to optimize the entire compressed air system. This final report, including all measurement results, can be used for energy management in accordance with ISO 50001.
Heiko Fleischhacker: I always advise companies that want to optimize their compressed air systems to take a structured approach. Because the various components function in direct dependence on each other, a holistic assessment of the compressed air system is of crucial importance. Selective changes at one point always have an impact on the performance and efficiency of the overall system. An optimally dimensioned compressor station loses its efficiency benefits if leaks and inadequate compressed air preparation cancel out these advantages.
In simple words: The energy efficiency of a compressed air system can only be successfully controlled with a holistic approach. With a compressed air energy efficiency audit, you create the necessary information basis for this. And just as importantly, you also receive a clear recommendation for the correct sequence of optimization measures.
Heiko Fleischhacker: An audit always makes sense if a company wants to obtain a neutral assessment and a precise status quo of the current condition of its compressed air systems. I recommend that companies undergo an audit to evaluate their compressed air systems, particularly in the context of DIN ISO 50001. On this basis, companies can meet the legal and normative requirements in a very targeted and economical manner. At the same time, they can continuously improve their own energy efficiency. In addition, we are increasingly receiving inquiries from companies who want to know more about the energy efficiency of their updated machines and systems before and after major changes. For example, installing new compressors or setting up new production lines. In both cases, an audit provides an excellent basis for improved operational efficiency. There are clear indications of where the reliability of the systems can be increased – often with simple means.
Heiko Fleischhacker: A good example of the effectiveness of our compressed air energy efficiency audits is a company that is part of Mativ, Inc. Here the compressors were incorrectly dimensioned and a higher-level compressor control system was missing. Thanks to a retrofit, we were able to adjust the operating times of the compressors much more precisely to the actual air pressure requirement. This has sustainably improved pressure control and energy efficiency. In addition, this adjustment has reduced the risk of pressure fluctuations and stabilized system performance. By systematically eliminating leaks, we have also created further savings potential. All of these measures have led to sustainable improvements. They have reduced energy costs and, above all, extended the service life of the systems.
Heiko Fleischhacker: Yes, absolutely! Maintenance and repair costs are often related to the incorrect design of a compressed air system. In many of our audits, I have observed that well-utilized machines can work for more than 20 years. If designed incorrectly, the service life of a machine can end after just 5 years. Targeted optimizations and regular checks as part of an audit avoid such expensive developments and can significantly improve the overall performance of the systems.
Heiko Fleischhacker: Companies must be able to trust that the results of their audits are a true and fair representation of their systems and processes. Neutrality is crucial, as it directly influences the credibility and acceptance of the audit results. Certified auditors like me are committed to neutrality. This means acting independently and objectively – we must not represent any personal or business interests. That is why we attach great importance to compliance with DIN ISO 11011, which sets out specific requirements for energy audits in compressed air systems.
Heiko Fleischhacker: Many customers value us for our many years of expertise in automation with pneumatics and electrics. We already pay close attention to energy efficiency when developing individual components. However, a comprehensive view of a company's overall systems offers the greatest benefit for our customers. Potential savings can be identified here and solutions for more efficient use of compressed air can be developed. Festo Energy Saving Services offer a customized range of services for interested companies. This ranges from an analysis of the current status quo to proposals for solutions and specific optimization measures for compressed air systems and installations on site.
Heiko Fleischhacker: Energy efficiency begins in the design and planning phase of machines and systems. It is important to understand where a valve terminal is best placed and what influence longer or shorter hoses have on my energy consumption. In my view, it is therefore crucial that companies are made aware of the long-term savings potential from the outset. A machine with integrated shut-off valves, for example, can be more expensive to purchase, but can quickly pay for itself over its life cycle through significant energy savings. We provide our customers with comprehensive advice right from the start of a project. Among other things, we use advanced simulation tools and digital planning instruments to ensure an efficient and future-proof system configuration. With this early and detailed planning, we support our customers in the development of powerful and energy-efficient systems.
We would like to thank Heiko Fleischhacker for the inspiring interview and the comprehensive information on the importance and implementation of compressed air energy efficiency audits in the manufacturing industry. His expertise and many years of experience have given us important insights into how companies can achieve significant energy savings and increases in efficiency by taking a holistic view of their compressed air systems.