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Energy optimization in compressed air generation: cost reduction and increased efficiency

Context and objective

In the industrial sector, compressed air generation is a major item of energy consumption, significantly affecting operating costs.

The company set the goal of reducing the incidence of electricity costs by more than 10 percent by optimizing the compressed air production system used by printers and packaging machines. To achieve this, a detailed analysis of consumption was conducted, identifying opportunities for improvement to make the process more efficient.

The intervention

Consumption analysis showed that the existing system could be optimized through more intelligent management of compressed air production. The intervention therefore included:

1

Installation of a variable speed compressor

It allows compressed air production to be modulated according to the required load, avoiding wasted energy.

2

Optimization of utilization of existing compressors

The remaining compressors are turned on only when full load is required, reducing consumption during lower demand phases.

The investment for the intervention was €90,000, with an economic return guaranteed by the energy savings and incentives obtained.

Results and benefits

The implementation of the new system has yielded concrete and measurable results:

Savings of 265,000 kWh/year

With a significant reduction in energy costs.

Obtaining TEEs

Which represent an additional economic advantage for the company.

Economic and operational impact

Reducing energy costs

Lower incidence of electricity consumption on compressed air production.

Increased operational efficiency

Optimized production according to actual need, avoiding waste.

Economic incentives through TEEs

Partial recovery of the initial investment through the mechanism of Energy Efficiency Certificates.

Sustainability and reduction of environmental impact

Lower energy consumption means an indirect reduction in CO₂ emissions.

The adoption of a variable-speed compressor has improved the efficiency of the compressed air generation system, providing significant energy savings and a reduction in the incidence of operating costs. With proper load management and access to TEE, the investment proved to be a strategic solution for optimizing the production process.

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