Industrial Air Utility Services

Nine out of ten industries use compressed air daily. Compressed air is absolutely essential to every aspect of manufacturing—from operating power tools to industrial lifting equipment and robotic paint booths. Yet, the importance of a reliable compressed air supply system is often overlooked. In-house compressed air systems can be expensive and difficult to maintain.

Compressed air has become the fourth utility for those who work in the industrial sector. The automotive industry truly depends on compressors. Compressed air is used when assembling vehicles, powering necessary tools, and when painting the vehicle. Just like any other essential component of a manufacturing plant, factory, or industrial plant, the air compressors should be serviced and kept in good conditions to ensure safety and efficiency. A faulty air compressor causes countless problems.

Compressed air is a widely used resource because it is safe and convenient; however, it can also be one of the most expensive energy forms. It is essential to take advantage of low-cost energy solutions to save money while increasing compressor reliability. It’s essential to look into supply lines, air storage tanks, air dryers, receivers, and after-coolers when considering air compressor efficiency. Proper system maintenance equates to significant energy and resource savings.

Many manufacturers overlooked compressed air costs for years when power was inexpensive, but as energy costs have increased significantly, it is imperative that facilities become educated about how important the total cost of ownership of their compressed air system is to saving money.

For example: A manufacturer operates a 200 hp compressor, 24 hours a day, 365 days a year. When the manufacturer installed the compressor, the energy cost was $0.04 per kWh and operating the compressor cost $55,031 annually. As the average electricity rate increases to $0.11 per kWh, the annual cost to operate the same compressor rises to $151,334. Facility managers have become charged with finding new solutions to reduce costs.

Optimized air delivery: Compressed air “utility” companies design systems specifically configured and calibrated for an individual plant’s load profile, which is achieved by measuring the free air delivery, load time, and total kWh of each air compressor. Optimized air delivery is the first step towards a more efficient air compressor system.

Lower operating costs: Even after taking the fees into account for outsourcing compressed air as a utility, there are significant financial benefits. Compressed air providers can achieve ideal air delivery to streamline compressor usage and yield significant energy savings compared to non-optimized air compressor systems. Total savings depends on the size, type, and number of air compressors in use.

Less overhead: In addition to lower operating costs, outsourcing compressed air services save a considerable amount of money on maintenance and service costs. Outsourcing compressed air places all of the associated service and maintenance costs on the compressed air provider. Not only does this represent additional cost savings but air compressor service technicians are immediately available to address any problems, reducing downtime and increasing profitability.

The reality is all compressed air systems leak, whether due to bad seals, oxidation, poor connections or any of dozens of other factors. Leaks in compressed air and vacuum systems cause significant expenses. In fact, leaks cause plants to lose an average of 20 to 40% of compressed air produced based on statistics from the US Department of Energy.

MPW Industrial Services can immediately identify and repair compressed air leaks, saving the customer time and money while also reducing CO2 emissions. MPW maintenance teams utilize acoustic SONASCREEN camera technology to locate leaks ten times faster than traditional methods. Sound sources are located in real time and the results are instantly analyzed to pinpoint even the most minute air leak. Larger areas can be scanned quickly for leaks as well.

Perfectly suited for use in industrial areas, MPW’s acoustic camera technology can be operated with no interruption to plant operation. Regular monitoring of compressed air and vacuum systems can lead to 20 to 30% energy cost savings.