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Energy Saving Services - detecting leakage

Festo Energy Saving Services

High energy prices, rising cost pressure and a growing awareness of climate protection undoubtedly make industrial energy efficiency a key business challenge for you. Festo’s Energy Saving Services to DIN EN ISO 11011 offer you a customized range of services for identifying and optimally exploiting potential compressed air savings, both systematically and sustainable.

Tailored to your needs: industrial energy efficiency as a modular service

The Festo Energy Saving Services have a modular design so they can precisely meet your specific requirements. You choose whether you want to take advantage of the PreAudit, just the individual service modules or the full audit. You define the objectives and we adapt the range of services to meet them.

PreAudit as navigator

You want to increase the industrial energy efficiency of your entire compressed air system, but do not know where to start? With our PreAudit, you detect weaknesses immediately and know reliably which measures are most likely to pay off in your compressed air system.

In the PreAudit, we examine compressed air generation and treatment, assess the compressor utilization, analyze the compressed air quality and measure the pressure drop in the system. In the quick check, we also perform a representative leakage detection on a machine and check the machine’s pneumatic efficiency. You get a detailed report with accurately documented data and recommendations for action weighted by priority. The documentation sets out the CO2emission values that many companies need to state in their sustainability report in accordance with GRI or GHG for example.

Audit: overview of the service modules

Energy Saving Service: service modules

1. Energy analysis of compressed air generation

Festo Energy Saving Services: condition monitoring

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, 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 clearly details energy costs and consumption, reveals power reserves, and specifies your potential savings.

2. Compressed air quality analysis

Festo Energy Saving Services: 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. This 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 right away.

This is possible because 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.

3. Pressure drop measurement

Festo Energy Saving Services: 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.

4. Pressure consumption analysis

Festo Energy Saving Services: compressed air 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 - only actual 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.

5. Leakage detection and elimination

Festo Energy Saving Services: determining leakage

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 expertly reviews 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. You can now finally put a number on your energy losses and CO2 emissions.

6. Machine analysis for industrial energy efficiency

Festo Energy Saving Services: 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 to estimate the costs, savings, and the expected amortization period of the possible measures. You get the results and recommendations in a 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 the

Energy Saving Services brochure (PDF).

Industrial energy efficiency brochure

Industrial energy efficiency at Festo means intelligent design, energy-efficient products and solutions, sustainable service and sound industrial education. Find out more in the

Industrial energy efficiency brochure (PDF).

Compressed air industrial energy efficiency audit to ISO/DIS 11011

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