Festo Energy Saving Services

In order to achieve the goal of energy-efficient compressed air generation, a clear, reliable consumption profile is required in line with the operating time. Only then can sizing and compressor running times be optimised.

This service consists of measuring power consumption and compressed air flow as well as the pressure level and bandwidth. The measurements are carried out during operation, independently of the manufacturer. This monitoring service documents the power and compressed air requirements as well as fluctuations in consumption between base load and peak load over several days. At the end, you will receive a detailed report that clearly sets out energy costs and consumption, reveals performance reserves and outlines your potential savings.

The quality of the compressed air has a direct effect on the operating costs. Oil, water or particles in the compressed air result in unnecessary energy consumption and shorten the service life of pneumatic components. This also throws doubt on the process reliability, and, in the worst case, results in sudden machine stoppage. On the other hand, an optimally sized compressed air preparation system saves energy costs straight away.

This can be achieved with a professional compressed air quality analysis, where we examine the centralised and decentralised compressed air preparation, measure the air temperature, pressure level and residual oil content and determine the pressure dew point. The final report provides you with clear recommendations on how to optimise compressed air quality.

The compressed air distribution in the system is frequently neglected and is an often underestimated cost factor with significant savings potential. In fact, you can save 8% of the energy for compressed air generation by reducing the pressure by 1 bar. In addition, a stable pressure level is essential for reliable processes.

During the pressure drop measurement, sensors use data loggers to simultaneously record the pressure profile at several points in the compressed air system. We also determine the pressure band and identify pressure drops. You will receive precise data and clear recommendations on the pressure reduction options available for your system.

The exact compressed air consumption per machine cycle is the crucial parameter for assessing the energy efficiency of machines and systems; it is also the basis for correct planning and sizing of the compressed air supply. Avoid pressure drops caused by undersizing as well as unnecessarily expensive oversizing. Only actual consumption measurements can tell you precisely how much compressed air your machines consume and how high the leakage rate is.

This service consists of measuring compressed air consumption and the pressure level at standstill and during operation as well as determining the average consumption and pressure level. You’ll find out where compressed air is being used inefficiently and what opportunities for improvement exist.

A leaking compressed air system wastes lots of energy and money and can jeopardise your process reliability. That is why detecting, documenting and eliminating leaks in compressed air systems are important efficiency measures.

With this service, we expertly inspect your entire compressed air system, from generation through to the pneumatic consumer, we detect leaks using high-sensitivity ultrasonic detectors during operation and classify them by size and costs. We also draw up detailed documentation including optimisation options and a list of recommended repairs in order of urgency. The report will be available to you online on our Festo Energy Saving Assessment Portal and provides you with a simple and structured way of monitoring the elimination of leaks. Last but not least, you can now quantify your energy losses and CO2 emissions.

Stabilise your processes and reduce your costs by strategically designing your compressed air system for the future.

During the machine analysis, experienced compressed air specialists measure the flow rate, consumption and pressure of the relevant pneumatic applications, determine inefficient compressed air usage and identify opportunities for improvement. Our experts use the analysis to define specific recommendations and also to estimate the costs, savings and the expected amortisation period of the possible measures. The results and recommendations are presented to you in a detailed report. We can also take care of the installation/modification of the developed solutions for you on request.