Nowadays, energy efficiency is a key issue for industrial companies worldwide. Rising energy costs and increasing environmental regulations are forcing companies to rethink and optimise their energy consumption. In this interview, Heiko Fleischhacker, Energy Efficiency Expert and Certified Auditor at Festo, explains the added value that companies can gain from a systematic compressed air energy efficiency audit. This is because the use of compressed air is often not considered, even though simple and sustainable energy savings can be achieved.
Heiko Fleischhacker: Energy efficiency is crucial for the competitiveness and sustainability of any company. However, when looking at compressed air systems, I always notice that the focus is often only on power consumption. Many companies already focus on energy-efficient lighting or photovoltaics, but the potential in a compressed air system is often overlooked.
When looking at energy efficiency in compressed air, they usually only consider the compressors. Discussions about high costs often centre on compressed air generation. However, the entire compressed air system, from generation to the use of the compressed air, must be analysed. Having a partial view means that valuable savings potential goes unrealised.
Heiko Fleischhacker: Producing, distributing and processing compressed air energy efficiently 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 don't know which adjustments they need to make in which order to achieve a sustainable increase in efficiency. Energy management and maintenance staff often lack the necessary expertise in pneumatics. Optimising compressed air is more than just eliminating leakages. It requires broad technological expertise and a thorough understanding of the compressed air system, from the compressor station to the pneumatic application. For example, a few weeks ago I carried out an audit at an established pharmaceutical company. The compressed air they produced was of a very high quality. But they never asked themselves if this was actually necessary for the production process. By making a small adjustment to the compressed air quality, we achieved extremely quick and sustainable energy savings. This shows once again how important it is to have a complete overview of the compressed air system, the compressed air requirements and an in-depth understanding of pneumatics.
Heiko Fleischhacker: A compressed air energy efficiency audit is an overall assessment of a company's compressed air system, from the compressor room to the pneumatic application. The goal of the audit is to identify areas where usage is inefficient and propose ways to save energy. This should reduce costs and CO₂ emissions, which in turn will increase productivity and improve sustainability. The audit provides a company with valuable insights and answers in several key areas. It shows how efficiently the compressed air is generated, how well the company's own compressors are utilised and how effectively the compressed air is routed through the system. It also identifies potential for improving infrastructure.
At the same time, the audit provides important information about the compressed air quality. This is crucial in order to meet production requirements and ensure machines perform reliably. The audit also shows how efficiently the compressed air is utilised in the various applications. At the end, companies receive a detailed report with precise data and prioritised recommendations for action that can be used to optimise 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 optimise their compressed air systems to take a structured approach. Because the various components are directly dependent on one another, a comprehensive assessment of the compressed air system is incredibly importance. Selective changes at one point always have an impact on the performance and efficiency of the overall system. An optimally sized compressor station loses its efficiency benefits if leakages and inadequate compressed air preparation cancel out these advantages.
In simple terms, the energy efficiency of a compressed air system can only be successfully controlled using an all-encompassing approach. A compressed air energy efficiency audit will provide you with the necessary information to do this. And, just as importantly, you also get a clear recommendation on which optimisation measures should be taken and in which order.
Heiko Fleischhacker: An audit always makes sense if a company wants to get an impartial assessment and a precise analysis of the current condition of its compressed air systems. I recommend that companies undergo an audit to assess their compressed air systems, particularly in the context of DIN ISO 50001. This will allow them to comply with the legal and normative requirements in a very specific and economical manner. At the same time, the company's own energy efficiency can be continuously improved. In addition, we are getting an increasing number of enquiries from companies who want to find out more about the energy efficiency of their updated machines and systems before and after major changes. For example, when installing new compressors or setting up new production lines. In both cases, an audit provides an excellent foundation for improved operational efficiency. There are clear indications of where the reliability of the systems can be increased, and often with simple means.
Heiko Fleischhacker: A good example of the effectiveness of our compressed air energy efficiency audits is a company of the group Mativ Inc. The compressors were incorrectly sized and there was no higher-level control system for the compressor. Thanks to a retrofit, we were able to adjust the operating times of the compressors much more precisely to the actual air pressure requirements. This has sustainably improved pressure control and energy efficiency. In addition, this adjustment has reduced the risk of pressure fluctuations and stabilised system performance. By systematically eliminating leakages, we have also created additional potential savings. All 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, exactly! Maintenance and repair costs are often linked to a compressed air system that has been incorrectly designed. During many of our audits, I have noticed that when machines are used in line with their capacity, they can work for over 20 years. If designed incorrectly, the service life of a machine may not be longer than 5 years. Specific optimisation and regular checks as part of an audit prevent these types of expensive situations and can significantly improve the overall performance of the systems.
Heiko Fleischhacker: Companies must be able to trust that the results of the audits are a true and fair representation of their systems and processes. Impartiality is crucial, as it directly influences the credibility and acceptance of the audit results. Certified auditors like me are committed to impartiality. This means acting independently and objectively; we cannot have any personal or business interests. That is why we attach great importance to complying with DIN ISO 11011, which sets out specific requirements for energy audits in compressed air systems.
Heiko Fleischhacker: Many customers appreciate our numerous years of expertise in automation with pneumatics and electrics. We already pay close attention to energy efficiency during the development of individual components. However, it's the comprehensive view of a company's overall systems that offers the greatest benefit for our customers. Potential savings can be identified and solutions can be developed for more efficient usage of compressed air. Festo Energy Saving Services offer a customised series of services for interested companies. This ranges from analysing the current status quo to proposing solutions and specific optimisation 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 what the best position for a valve terminal is and what influence it has on energy consumption, whether tubes will be longer or shorter. That is why, in my view, it is crucial that the companies are aware of the long-term savings potential right from the start. A machine with integrated shut-off valves, for example, can be more expensive to purchase, but can quickly pay for itself over its product life cycle thanks to 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. During such an early and detailed planning phase, we help our customers develop systems that are both high-performing and energy-efficient.
We would like to thank Heiko Fleischhacker for the inspiring interview and the exhaustive information on the importance and application 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 an overall view of their compressed air systems.