Energy Management in Compressed Air Systems

CS Instruments’ reliable energy management solutions enable accurate monitoring and early detection of inefficiencies, optimising compressor performance and air quality to help you achieve maximum energy savings and system longevity. Our measuring devices for various applications play a key role in monitoring and optimising energy consumption. Contact us today to learn more about our energy management solutions!

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1. ENERGY MANAGEMENT IN
COMPRESSED AIR SYSTEMS
ENERGY MANAGEMENT IN
COMPRESSED AIR SYSTEMS
PRECISION. EFFICIENCY.
SUSTAINABILITY.Website www.cs-instruments.com/za

2. Introduction: The Role
of Energy Management
Optimising the efficiency of compressed air systems is crucial for
industrial applications, and measuring devices from different
categories play a key role in monitoring and optimising energy
consumption. CS Instruments’ reliable compressed air meter
enables accurate consumption measurements, and the compressed
air quality monitors measure humidity, particles, and oil content
to ensure that the compressed air meets the required standards.
Our leak detection devices localise leakages and help reduce
energy loss, while our dew point transmitters continuously
monitor humidity and temperature to prevent condensation and
damage.

3. 1.Measurement Setup: Install accurate flow and consumption
meters at key points in main lines for reliable data collection.
2.Data Recording: Measure air consumption, pressure, dew point,
and power usage using intelligent chart recorders like the DS
500.
3.Leakage Detection: Identify air losses during the period from
Friday to Friday in order to obtain the consumption data of the
compressed air systems for a complete production period.
4.Comprehensive Evaluation: Analyse trends and performance
data to detect inefficiencies and boost energy usage across
systems.
Four Steps to Analysing
Compressed Air
CS Instruments provides customised solutions
for reliable compressed air analysis:

4. Improving Energy Efficiency
(Step 1)
To permanently reduce energy requirements, a two-stage
approach is recommended.
Step 1: Minimise the compressed air demand
caused by production and leakages.
1.Choice of automation technology: use of electric motors vs.
pneumatics
2.Simple movements: Electric drives are preferred for efficiency
and precision.
3.Press-in processes: Choice between pneumatics and electrics
depending on process force and process duration.
4.Holding forces: Pneumatics are more efficient, as electric drives
constantly consume energy for positioning.

5. Optimising System Operation
(Step 2)
Step 2: With a clearly defined requirement,
production and treatment can be optimised in
terms of energy, ensuring that compressors and
treatment are efficiently designed to meet the
actual, minimised demand.
Compressor Control
Heat Recovery
System Maintenance
Pressure Optimisation
Pipeline Design
Compressed Air Treatment
Desiccant Dryers

6. Factors Influencing
Efficiency
Factors Influencing
Efficiency
Intake Conditions: Temperature, humidity, ventilation, and
absolute pressure affect performance.
Compressed Air Tanks & Pipelines: Proper sizing stabilises
pressure and prevents losses.
Compressed Air Treatment: Ensure correct drying and
filtration in line with ISO 8573-1 standards.
Desiccant Dryers: For extremely dry air requirements (dew
point < -40°C), desiccant dryers enhance system reliability and
air purity.

7. The Cost of Compressed
Air
The Cost of Compressed
Air
Understanding the cost breakdown helps in making informed
decisions:
Acquisition Costs: 10–15%
Energy Costs: 70–75% (largest expense)
Maintenance Costs: 10–15%
To assess efficiency, measure over a full week to capture all operating
conditions. Continuous monitoring ensures accurate data, energy
transparency, and long-term savings.

8. Conclusion: Smart Energy
Management with CS
Instruments
Conclusion: Smart Energy
Management with CS
Instruments
CS Instruments’ reliable energy management solutions enable
accurate monitoring and early detection of inefficiencies,
optimising compressor performance and air quality to help you
achieve maximum energy savings and system longevity. Our
measuring devices for various applications play a key role in
monitoring and optimising energy consumption. Together, these
systems make a significant contribution to optimising the
efficiency of compressed air systems. Contact us today to learn
more about our energy management solutions!

9. THANK
YOU!GET STARTED TODAY! www.cs-instruments.com/za