How compressed air is shaping a smarter, greener future for industry

02 April, 2025

Repair is also a critical consideration. Up to 20% of the energy consumption in a compressed air system can be lost to air leaks. These days, fixing leaks while the distribution net is under pressure and without dismantling pipes or couplings is possible. Then, by investing in the latest intelligent control systems, connectivity and advanced monitoring tools, it is possible to optimise the operation of compressed air systems while set pressure and flow are being met.

Sensor-based compressor control systems, for instance, can significantly increase the efficiency of the whole air compressor system by actively managing the integrated machines at their most optimum points possible – thereby reducing energy consumption and optimising maintenance needs. Remote monitoring systems also allow end users to monitor the performance of their air compressor from a computer, smartphone, or tablet. Smart diagnostic systems allow for the capture of live data from compressed air equipment and the translation of it into clear insights. This means end users can check uptime, energy efficiency, and the health of a complete compressed air installation at a glance.

The importance of variable speed drive designs

Advances in modern air compressor design have also addressed energy efficiency. Over the past two decades, air compressors with Variable Speed Drives (VSD) have emerged to maximise energy efficiency and deliver energy savings. This type of design automatically adjusts the compressor’s operating speed to match compressed air production to demand in real-time. This is particularly useful in operations where demand for compressed air fluctuates, such as facilities that operate different processes or multiple shifts, so flow demand increases and decreases throughout the day.

So, how do VSDs work? An inverter adjusts the compressor’s speed (RPM). Instead of all the power going directly into a traditional AC fixed-speed compressor running at full capacity, the inverter provides the VSD compressor with the specific voltage required. Electronics measure system pressure and an onboard controller adjusts motor speed to match actual air demand. It’s a simple idea, although the technology that makes it possible is extremely sophisticated.

Standard VSD units are equipped with induction motors coupled to the screw elements with gears, but the latest VSD technology features an interior Permanent Magnet motor. Here, the iPM motor shares a rotor with the screw elements. That means it’s direct drive, making it extremely energy efficient. The whole drive train is a closed circuit, where both the motor and elements are cooled with oil, another good way to save energy. Compressors with the iPM technology reduce energy consumption by 50% on average compared to an idling compressor. The new technology also features a vertical design concept, which reduces the footprint by up to 55% compared to traditional air compressors.

Why reliability supports sustainability

Coupled with the need to improve energy efficiency is the desire to have more reliable air compressors. Equipment is only useful if manufacturers can rely on it to perform consistently, day in and day out. A focus on reliability ensures uptime, reducing the chance of production halts caused by faulty equipment.