Many compressed air systems run at a higher pressure than the process needs, often out of habit or to mask pressure drop. Every 1 bar of unnecessary pressure adds about 7% to compressor energy consumption, so lowering the setpoint is one of the cheapest energy savings available.
Find the real requirement
Measure the pressure actually needed at each point of use and identify the highest requirement. Then measure the pressure drop across the network between the compressor room and that point. The minimum setpoint is the required point-of-use pressure plus the network pressure drop.
Lower it safely
- Fix the worst pressure-drop points first, such as undersized pipes and clogged filters
- Reduce the setpoint in small steps and watch production
- Use a pressure controller to hold a stable band
- Verify the most demanding tool still reaches full performance
The payoff
Cutting 1 bar from a large system saves roughly 7% of compressor energy with no capital cost. Where pressure drop is the real problem, fixing the pipework and filters delivers the same pressure at the tools with even lower energy use.