Furniture Company Saves $75,000
In Annual Energy Costs with MANAGAIR® 

Overview

A leading North American furniture manufacturer was facing mounting inefficiencies from running six air compressors across three facilities. Two of the plants were connected, yet the air systems operated independently, leading to pressure instability, unnecessary runtime, and higher energy costs. With each compressor partially loaded and no centralized control, the operation lacked efficiency, consistency, and visibility.

To gain control over performance and reduce energy waste, the manufacturer implemented MANAGAIR®, an OTC Industrial Technologies Product that provides predictive maintenance and automation solutions.

The result: increased efficiency, better pressure stability, and over $75,000 in annual energy savings.

  • Customer: Furniture Manufacturing
  • Length of Relationship: 3 years (since 2022)

Results:

$75,000 in verified annual energy savings

Increased uptime through real-time diagnostics and system optimization

Improved pressure stability across all connected facilities

Reduced compressor cycling and maintenance interventions

Enhanced system scalability without added infrastructure

Challenges

The manufacturer’s compressed air system included six compressors across three buildings, each running without centralized logic or coordination. This setup introduced key challenges:

  • Partial loads caused compressors to run inefficiently
  • System-wide pressure drops impacted production and quality
  • Lack of centralized control led to wasted energy and inconsistent operation
  • Facilities were unable to scale or balance performance across locations
  • Maintenance scheduling and compressor cycling were unpredictable and labor-intensive

With no shared data or intelligent load management, energy costs continued to rise—even though demand hadn’t changed.

Solution

The manufacturer partnered with OTC to evaluate the entire compressed air infrastructure. After a comprehensive plant audit, OTC integrated MANAGAIR®, Advanced Central Control software that brings smart, logic-based control to multi-compressor environments, including predictive maintenance.

MANAGAIR® continuously balances load, manages sequencing, and provides real-time system visibility across all compressors, regardless of brand. By coordinating compressor performance as one system, rather than six isolated units, MANAGAIR® helped the manufacturer unlock immediate operational improvements and increased operational efficiency.

Conclusion

In multi-building manufacturing environments, decentralized compressor management can lead to major inefficiencies. MANAGAIR® solved this by delivering centralized logic, monitoring, and optimization, all without replacing a single compressor.

With smart, advanced central controls now in place, this furniture manufacturer has the visibility, air efficiency, and savings it needs to run leaner and grow smarter.

MANAGAIR®: Advanced Central Controls for Compressed Air Systems

Whether you're running two compressors or twenty, MANAGAIR® helps you centralize control, reduce energy costs, and gain real-time insights that improve uptime and performance across your entire facility.

👉 Learn more at directair.com/managair