Energy Saving Services – detecting leakages

Festo Energy Saving Services

High energy prices, rising cost pressure and a growing awareness of climate protection have undoubtedly made industrial energy efficiency a key activity in your business. Festo Energy Saving Services according to DIN EN ISO 11011 offer you a tailor-made range of services that enable you to identify and utilise potential compressed air savings in an optimal, integrated and sustainable way.

Tailored to your needs: energy efficiency as a modular service

The Festo Energy Saving Services are offered on a modular basis to precisely meet your specific requirements. You can choose whether you want to take advantage of the PreAudit, only individual service modules or a comprehensive audit. You define the objectives and we adjust the scope of services accordingly.

PreAudit as your guide

Would you like to increase the energy efficiency of your entire compressed air system, but aren’t sure where to start? Our PreAudit enables you to immediately identify weak points and know for certain which measures are most likely to bring results in your compressed air system.

During the PreAudit, we examine compressed air generation and preparation, assess compressor utilisation, analyse compressed air quality and measure the pressure drop in the system. In the quick check, we also carry out a representative leakage detection test on a machine and check the machine’s pneumatic efficiency. In addition, you will receive a detailed report with full documentation of the data and recommended actions weighted in order of priority. The documentation contains, among other figures, the CO2emission values that many companies require for inclusion in their sustainability reports, e.g. in accordance with GRI or GHG.

Audit: the service modules at a glance

Energy Saving Services: service modules

1. Energy analysis of compressed air generation

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.

2. Compressed air quality analysis

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.

3. Pressure drop measurement

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.

4. Compressed air consumption analysis

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.

5. Leakage detection and elimination

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.

6. Machine analysis for industrial energy efficiency

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.

Energy analysis of compressed air generation

A unique, reliable consumption profile appropriate to the operating time is required in pursuit of the goal of energy-efficient compressed air generation. Only then can sizing and compressor running times be optimized.

This service consists of measuring power consumption and compressed air flow as well as the pressure level and bandwidth. The measurements are performed during operation and independently of manufacturer. This monitoring documents the power and compressed air requirements as well as fluctuations in consumption between basic and peak load over several days. At the end you get a detailed report that makes clear the energy costs and consumption, reveals power reserves, and specifies your potential savings.

Compressed air quality analysis

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 lifetime of pneumatic components, which calls the process reliability into question, and, in the worst case, results in sudden machine stoppage. On the other hand, optimally sized compressed air treatment saves energy costs straightaway.

This is possible on the basis of a professional compressed air quality analysis where we examine the centralized and decentralized compressed air treatment, measure the air temperature, pressure level and residual oil content, and determine the pressure dew point. The final report gives you clear recommendations of how to optimize the compressed air quality.

Pressure drop measurement

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

During the pressure drop measurement, sensors simultaneously record the pressure curve using data loggers at several points in the compressed air system. We also determine the pressure band and identify pressure drops. You get precise data and clear recommendations on your options for reducing pressure in your system.

Pressure consumption analysis

The exact compressed air consumption per machine cycle is the crucial parameter for assessing the industrial energy efficiency of machines and systems as well as the basis for correct planning and sizing of the compressed air supply. Avoid pressure drops due to undersizing as well as unnecessarily expensive oversizing because only real consumption measurements can tell you precisely how much compressed air you machines consume and how high the leakage rate is.

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

Leakage detection and elimination

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

This service consists of expertly reviewing your entire compressed air system from generation through to the pneumatic consumer, detecting leaks using high-sensitivity ultrasonic detectors during operation, and classifying them by size and costs. We also draw up detailed documentation complete with optimization options and a list of recommended repairs in order of urgency. We make this available to you online in our Festo Energy Saving Assessment Portal, which provides a simple and structured way of monitoring the elimination of leaks. Not least you can now put a number on your energy losses and CO2 emissions.

Machine analysis for industrial energy efficiency

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

The machine analysis consists of experienced compressed air specialists measuring the flow rate, consumption, and pressure of the relevant pneumatic applications, determining inefficient compressed air usage, and identifying opportunities for improvement. Our experts use the analysis to define concrete recommendations and also estimate the costs, savings, and the expected amortization period of the possible measures. You get the results and recommendations in detailed documentation. We look after the installation/modification of the developed solutions for you on request.

Energy Saving Services brochure

You will find an overview of the individual service modules as well as a customer reference in our

Energy Saving Services brochure (PDF).

Energy efficiency brochure

Energy efficiency at Festo means intelligent design, energy-efficient products and solutions, sustainable service and well-founded industrial training. Find out more in our

Energy Efficiency brochure (PDF).

Compressed air energy efficiency audit to ISO/DIS 11011

TÜV Süd certification (German Technical Control Board) (PDF)

Successfully implemented energy efficiency