Compressed Air System Audits

Compressed Air Audits Compressed air systems are essential to continuous operation for many manufacturing processes, but it is often taken for granted that the system is always on, functional and readily available. Like electricity or tap water, compressed air is expected to flow automatically at the flip of a switch or the turn of a knob. However, these systems require service, maintenance, and technology updates to continue operating clean, leak-free, and efficiently. Having your compressed air system audited regularly ensures not only it stays on and immediately accessible, but it is also functioning at its optimal best. Through improvements in energy consumption, savings in operational costs and reductions of down times, a compressed air audit can provide a quick return on investment.

What is a Compressed Air Audit?

Compressed air systems are robust, which is good news for capital equipment costs. However, that longevity also means many components are aging and made with decades old technology. While the heart of any compressed air system is its air compressor, the system also includes intake filtration, aftercoolers, storage tanks and air dryers which all have numerous valves, regulators, drains, traps and miles of piping and hoses. An iZ Systems compressed air system audit not only evaluates the system to identify components that are mis-sized, dirty, corroded, leaking or even non-functioning, it also identifies areas where aging components could be replaced with updated technology that can improve performance.

However, auditing a compressed air system isn’t just about identifying what is broken and updating to new technology, it is about making sure the system fits your company’s needs. When the compressed air system was installed, it was designed for the workflow and processes that existed at that time. Some considerations for growth or changing process needs may have been included, but it is likely the system’s performance no longer matches your current operational needs.

The Benefits of Compressed Air Audits

Compressed Air System Audits Operational mismatches can permeate throughout a facility. It is possible that machinery was added or moved, and the compressed air piping was not resized. The order of manufacturing operations may have morphed over time increasing or decreasing peak loads on the compressed air system. Certain processes might have changed over time and the compressed air system was not adjusted to match the changes. Perhaps the compressor is aging quickly because it is being overworked. It might frequently cycle on and off to maintain adequate compressed air storage during peak operations. Alternatively,  maybe it isn’t peak conditions causing the problem, but rather silent leaks forcing the compressor to cycle. Maybe the compressor operates at higher than recommended pressures due to uncalibrated or malfunctioning controls systems or because intake air filters and valves are too restrictive for the necessary airflow.

There are many reasons why a compressed air system may not be performing at its optimal best. An iZ Systems compressed air system audit pinpoints the inefficiencies and problems in the system while also identifying where the biggest opportunities for improvement exit to ensure all improvements offer significant cost benefits.

Industries that Benefit from Compressed Air Audits

A compressed air system audit is designed to optimize the system in conjunction with the company’s processes. Rather than just accounting for peak loads, an audit analyzes how a manufacturing facility is designed and how it operates throughout a timeframe. From this analysis, auditors suggest targeted improvement that can provide the most return on investment.

The goal is not to just update to the latest and greatest technology. Compressed air is used in a wide variety of industries including:

Plastic Molding Paper Mills/Pulp Mills Cement & Powders
Electronics Paper Converting Pharmaceuticals
Automotive Printing/Envelop Tire, Rubber & Elastomers
Food Processing Plywood and OSB Mills Chemical/Process Industries.

With such a broad range of applications, there is not a single solution that will work for everyone. A compressed air system audit is about identifying the solutions that fits a specific facility’s needs, budgets and goals.

How Compressed Air Audits Can Help Your Bottom Line

Ultimately, the real goal of an iZ Systems compressed air system audit is to identify cost reductions and process improvements.  Savings can be realized in the following ways:

  • Performance Optimization – Reduce energy consumption through efficiency gains
  • Equipment Longevity – Reduce compressor cycling and
  • Controls and Automation – Operate at or below recommended loads
  • Improvements and Enhancements – Updated technology where it offers the most benefit
  • Visualization – Insight into operations for continuous improvement

What Makes iZ System’s Air Process Unique

Compressed Air Audits iZ Systems compressed air audit is more than just an audit that locates problems. We offer comprehensive turn-key implementation with on-site professionals. The analysis is completed in person and takes into consideration your company’s entire operations. The results of the audit are provided with tailored action plans to fit your needs, budgets and goals. iZ Systems manages the implementation including all the necessary sourcing and, when necessary, we coordinate with energy providers to get rebates and complete energy savings applications. Finally, our professionals provide the necessary training to ensure seamless implementation.

Other Ways iZ Systems Can Help Your Business

In additional to compressed air system audits, iZ Systems provides service for all your air handling needs. We can improve the energy consumption and efficiency of a low pressure high volume, audit vacuum systems and offer training and seminars about improving air system operations.

For more information, contact us today.