Compressed air system performance issues such as inadequate or unreliable pressure, can cause extended downtimes, disrupt operations, and negatively impact productivity.
DIRECTAIR® knows the importance of having high-quality and reliable compressed air systems to help achieve production goals. For 30 years, DIRECTAIR® has provided worry-free compressed air solutions to keep systems running smoothly and eliminate unplanned operational downtime and maintenance repairs.
As you begin to evaluate your current compressed air system, consider these nine tips from DIRECTAIR® that can lead to long-term solutions for your compressed air challenges.
Unlocking Efficient Compressed Air Systems for Manufacturing
When first evaluating your compressed air system, consider it a critical utility like electricity or gas. Consistent and reliable service is essential for maintaining productivity and operational efficiency.
Perform an Air Audit with Expert Consultation
Conducting an air audit is crucial for identifying issues and opportunities for improvement. DIRECTAIR® provides flexible audit options tailored to your preferences: our experts can perform the audit directly and review the results and recommendations with you, or we can connect you with an independent, third-party compressed air audit consultant. These consultants deliver a comprehensive technical and financial analysis customized to meet your system's specific needs.
An air audit not only identifies leaks but also helps determine the current and future needs of your system. From calculating air usage, uncovering inefficiencies in pressure, flow, and energy use, and assessing your peak demand system capacity, audits ensure that you are getting the most out of your equipment. This comprehensive and flexible approach is designed to guide you toward a "win-win" solution by capturing realistic economic evaluations tailored to your facility's requirements.
Implement an Industrial Compressed Air Solution
From the air audit, identify the issues causing an inconsistent, or unreliable compressed air supply. Depending on the issues uncovered, there are a few options for your next course of action.
1. Compressed Air Leakage Audit
Perform regular checks to ensure there aren't any leaks coming from hoses, tubes, fittings, pipe joints, couplings, valves, or quick disconnects. It's important to note that even a small leak can lead to significant energy loss. For example, a 1/8-inch leak in a compressed air line could cost a business hundreds of dollars annually in lost energy.
2. Review Compressed Air Operation Standards
When dealing with compressed air equipment, consult the manufacturer to establish baseline operating guidelines. This includes determining maintenance downtime requirements. Use this information to create an effective operational schedule.
3. Evaluate Compressed Air Pressure
When faced with inadequate compressed air supply, avoid the temptation to increase air pressure. Instead, focus on identifying and addressing the root problems. Raising pressure levels without addressing system inefficiencies can lead to higher energy costs and additional wear on your equipment.
It's essential to recognize that raising the pressure will lead to higher energy costs. Conversely, a mere reduction of 2 PSI in compressor output pressure can result in up to 1% energy savings.
4. Install a Monitoring System
Keeping track of your air usage, while identifying potential problems before they occur, can help you avoid production stoppages. A monitoring system can help you optimize your system's efficiency and reduce your energy consumption and associated costs.
DIRECTAIR® provides real-time alerts for pressure drops or equipment malfunctions, enabling any issues to be addressed before they result in costly downtime.
5. Upgrade Compressed Air Piping
If your piping is too complicated or inadequate, your compressed air will struggle to reach your end users. Work with a compressed air expert to evaluate your piping and implement system upgrades when necessary.
Optimizing the diameter and layout of your piping is critical to reducing pressure drops, minimizing energy loss, and ensuring efficient delivery of compressed air throughout your facility.
6. Change Filters
Pressure drops may occur due to an incorrectly sized, or clogged filter. To address this, check the filter's condition to ensure it's clean and fits properly. Dirty or undersized filters can restrict airflow, increasing the strain on your system and reducing efficiency. Additionally, consider implementing a maintenance schedule for regular filter replacements.
7. Add an Air Dryer
Moisture can cause problems with your compressed air system. If you live in a humid climate, an air dryer can remove the moisture from the air, which helps your compressor run more efficiently. Incorporating an air dryer into your system can prevent moisture-related issues like rust or corrosion, extending the life of your equipment.
8. Compressed Air System Rentals
Renting an air compressor can be a great option for businesses that don't have the upfront capital to purchase their own equipment or for companies that only use compressed air intermittently. Rentals are also useful for short-term needs, such as during system upgrades or scheduled maintenance, allowing you to avoid operational downtime.
When renting, be sure to choose a reputable company with high-quality equipment, such as OTC Rental.
9. Purchase the DIRECTAIR® Utility Solution
Moving to DIRECTAIR® can be a great way to improve your compressed air system and eliminate all the challenges you have with compressed air supply.
DIRECTAIR® is a utility solution that delivers high-quality, reliable compressed air systems that are designed, manufactured, monitored, maintained, and operated by DIRECTAIR® in customers' facilities.
This service eliminates the need to purchase and replace an on-site air compressor, as well as the worries about costly maintenance. With the DIRECTAIR® solution, customers can save up to 50% on energy costs by optimizing system performance and reducing inefficiencies.
Evaluate Your Compressed Air System with DIRECTAIR®
Take the time to properly evaluate the issues with your compressed air system and implement a long-term solution with DIRECTAIR®. Temporary fixes often result in greater costs over time and can negatively impact production efficiency. Solving the root of the cause the first time can save you time and money.
Contact DIRECTAIR® for assistance in determining the best option for your manufacturing needs. Request An Air Audit Today.