Projects

We believe in measuring results. For every project, we establish a baseline with the initial audit data. After improvements, we often perform a follow-up measurement or analysis—this could involve temporary metering of the compressors again or reviewing utility bills to compare before-and-after performance. In one example, a steel plant’s post-project data confirmed a 33% drop in energy consumption – exactly what our model predicted. This verification gives hard proof that the optimizations delivered the expected outcomes. 

Energy reductions of 20–50% are very common. In some cases where systems are already efficient, savings might be only around 10–15%. In others, especially inefficient setups, over 50% can be saved. On average, many clients see roughly a one-third reduction in compressed air energy use. Every facility is unique, but there is almost always substantial room for improvement. 

The GHG emissions reduction generally goes hand-in-hand with the energy savings. If you use less electricity, you produce fewer emissions. In other words, a 30% energy savings usually means about 30% lower CO2 emissions from your compressed air system. For example, the 41% energy reduction at the brick manufacturing plant also meant a 41% reduction in yearly greenhouse gas emissions. Compressed air optimization is a powerful way to support sustainability and climate goals while saving money. 

Not always. In many cases, we can dramatically improve efficiency by optimizing the existing equipment and system setup. Actions like fixing leaks, adjusting controls, adding storage receivers, or improving maintenance can go a long way without needing to purchase a new air compressor. We only suggest new equipment if the data shows it’s truly cost-effective. For instance, a new VFD compressor was essential in one automotive plant to achieve a 63% energy reduction. But if your current hardware can be tuned to perform efficiently, we focus on that first.

Projects usually pay for themselves very quickly. Many low-cost fixes, like adjusting controls or repairing leaks, have near-immediate payback. More involved improvements typically see payback times on the order of 1 to 3 years. Indeed, many projects fall in the 1–2 year payback range. For example, one plant had options with ~1.5 year paybacks for nearly 50% energy savings. Even larger investments like a new compressor or a big storage tank often pay off in under 3 years due to the significant energy cost reduction.