January 18, 2022

Compressed air assessments are a standardized process for air compressors that you shouldn’t overlook in your plant or facility. Air compressors need occasional monitoring and maintenance to ensure they’re performing at peak capacity and free of impurities. When your air systems perform better, you save money on energy and machines.

It’s more than that. When air compressors are operating well, you’re protecting your air compressor investment. You may even save unnecessary costs on buying a new machine.

That’s where an air demand analysis (ADA) comes in to ensure peak performance and to help project potential future energy, maintenance, and repair savings.

Read on to learn what it is, the benefits, and how to get started.

What is ADA?

An ADA is an in-depth audit that is performed by our factory trained technicians using a multitude of measurement tools. Such as sensors, transducers, meters, and data logging equipment. Using this equipment, your compressors operation is monitored for up to 14 days. During this time, our equipment is monitoring and logging your compressed air system’s pressure, flow, KW, leak rate, and artificial demand. All without interrupting your daily plant operations.

After completion, the data and equipment are retrieved, and the data is shared with Kaeser’s System Engineers. We work with these engineers to generate robust reports outlining the operational values of the compressed air equipment, then provide the customer with an overview and discuss possible improvements in operational settings and/or upgrades which would offer an exceptional ROI.

Why do you need an ADA?

Whether you’re considering adding equipment for an upcoming expansion, curious about energy savings and rebates, or just want to better understand how your compressed air system is really working, an ADA is a great tool to assist with finding the answers you are looking for. 

Benefits of an ADA

An ADA has benefits for manufacturers and consumers. Kaeser indicates an ADA can save you money by:

  • Helping your company achieve operational excellence
  • Potentially eliminating the need for a new compressor, saving you money
  • Reducing your carbon footprint meeting company standards, enabling you to compete for green customers
  • Qualifying your company for a utility rebate
  • Gaining efficiency while reducing costs, including energy costs (potentially up to 50%)
  • Reducing leaks and issues

It’s all about ensuring your machine is efficient and effective.

ADA measurable results

Need further reasons to sign up? Data from the Department of Energy Findings make it clear how much you can gain and save by performing an ADA audit and improving your compressed air system. Here are some stats about air compressors in the US to highlight measurable areas of opportunity for saving:

  • Compressors use up to 10% of all generated electricity in the US
  • Approximately half of all compressed air is wasted
  • Anywhere between 25-50% of all compressed air is lost through leaks
  • 15-25% of all compressed air is wasted through artificial demand and inappropriate uses
  • 70% of compressed air operating costs is from power
  • One 125HP compressor consumes about $95K in electricity per year based on full-time operation at the US average cost for industrial electricity

That’s a lot of potential wasted energy and money spent. An ADA significantly reduces energy costs by identifying problems to eliminate. But to eliminate inefficiencies in your system requires partnering with someone (like Kaeser’s team) that assists with righting any wrongs.

What to expect from your ADA?

It’s easy. In our process, our Account Manager makes the initial site visit, provides for all recommendations, and presents the reports. From there, our experienced technicians can also discuss improvements and preventive maintenance based on your set up and the environment.

Get started today

At Palmetto Compressors, we have technicians with 80+ years of combined experience. We’ve even conducted ADAs for some of the most impressive companies in the U.S.

But we do more than just ADAs. We service all major brands in a variety of ways and are a distributor of Kaeser air compressors, the gold standard. We design the best air systems in South Carolina. And we do installs.

Ready to improve your air system? We are, too! Schedule your ADA today.

October 7, 2021

In the air compressor business, air is sometimes called the fourth energy source. Air compressors keep your business going and get your company’s products out and services delivered, on time and on budget.

But air compressors aren’t cheap. You’re getting compressors at a premium so you want to ensure that you’re protecting your investment. Protecting that investment is why preventive maintenance is so important.

Best practices for preventive maintenance

In general, you should have your air compressors serviced at least once a year or for every 2,000 – 3, 000 hours of service. In addition, extreme weather conditions – caused during winter and summer – are great times to get your air compressor serviced. Summers in South Carolina can be brutal. But these days, winters aren’t that great either! Cold snaps have been known to shut down cities and cause havoc on companies trying to manufacture goods or keep packages moving. A maintenance technician can help you determine what that cadence is for your facility.

kaeser compressors

Routine maintenance typically includes:

  • Fittings and belts tightened and inspected
  • Oil changed
  • Filters changed
  • General inspections
  • Cleaning of all coolers and drains
  • Collection of oil samples for testing
  • Recording amp draw
  • Recording voltage
  • Checking for abnormal vibrations and noise
  • Injection and discharge oil temp
  • Lubricating drive motor bearings

Why preventive maintance?

Maybe people, other than you, at your company need convincing your air compressor needs maintenance. We have a few thoughts that go beyond protecting your investment.

1. Reduce costs on replacing a compressor while increasing efficiency and protecting your investment

When you spend money on an air compressor, you want something that will last. Kaeser, known for quality, is built to power your plant. And typically, plant managers know that type of quality costs.

But even Kaeser air compressors need maintenance. More than that, by checking on your air compressors, you can gain effiency … and reduce further costs on new air compressors. Read what happened to one auto shop that couldn’t keep up with customer demand due to delayed maintenance.

2. Keep your facility running

When you don’t take care of something (a car, appliance, etc.), it breaks. Air compressors aren’t any different. But when air compressors break, your entire facility could completely grind to a halt. That stopping of operations costs your company time and money.

It could even impact your customers. If your plant falls behind, your customers may not get the goods or services they requested from your company. That dissatisfaction may impact future purchasing decisions.

It could also affect labor, sidelining them as you scramble to determine what happened. Depending on your company policies, workers could get paid even though the shop isn’t running. That eats away at profits.

Then there’s the emergency cost from the technician. If the call happens on a weekend or after business hours, most air compressor companies tend to charge more. Although Palmetto Compressors would be happy to help you handle those late night and weekend repairs, we don’t recommend customers wait for that scenario. Besides, our goal is to ensure you’re taken care of. That’s why customers typically choose us.

3. Reduce worker injuries and fines

Air compressors that aren’t maintained can be dangerous, causing serious issues. Those issues vary wildly from hearing damage to killing a worker.

Workers injured on the job file worker’s compensation claims and potentially want to take legal action for lack of maintenance. OSHA has standards for how air compressors are used in facilities, even where they’re used. Violations of those OSHA standards can be expensive; OSHA fines are up to $70,000 per violation.

For safety and concern for the bottom line, companies should maintain their air compressors.

Palmetto Compressors can help your South Carolina business

There are many good reasons to have your air compressors on a maintenance schedule. Palmetto Compressors is in South Carolina helping businesses just like yours for many years. Opeating out of Fountain Inn (near Greenville, SC), our people have an excellent reputation in the state and can handle your preventive maintenance needs … or your emergency air compressor demands. Our goal is ensure your air compressor and facility doesn’t get to a point where it needs emergency work so your plant keeps running.