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 efficiency as a modular service
Customised and certified
Festo Energy Saving Services, certified in accordance with DIN EN ISO 11011, offer you a customised range of services that provide you with an up-to-date report on the condition of your compressed air systems and equipment. This independent and impartial assessment gives you a detailed overview of possible savings potential and valuable recommendations and actions to maximise this potential.
- Increase your production stability
- Reduce your energy costs
- Achieve your environmental goals
Your benefits at a glance
Pneumatic applications often offer considerable savings potential in terms of compressed air consumption and the associated energy costs. That's why our energy efficiency experts take a close look at your systems to find out whether they are energy efficient, or are maybe consuming too much compressed air.
Increase your production stability
- Enhance the stability of your production processes in the long term
- Avoid unplanned machine downtime and production losses
- Get an optimised status report of your systems and equipment
- Maintain the service life of your machines
Reduce your energy costs
- Increase your profits through optimised compressed air consumption
- Benefit from more efficient compressed air generation
- Utilise potential savings by avoiding pressure losses
- Improve your CO₂ footprint and comply with regulatory requirements
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Do you want to find out more?
Wewould be happy to answer any other questions you may have about Festo Energy Saving Services at any time. Just get in touch with us. We look forward to hearing from you!
