Making Your Air Compressor More Efficient


There are 4 utilities that every manufacturing company needs to think about and how much is being used or wasted. The first three are easy to name- water, electricity, and natural gas. The 4th major one would be compressed air, and it is the one that is easily forgotten. Sawyer Compressor is here to help to examine and explain to you several opportunities for reducing your plant’s energy draw, which will result in significant energy savings, lower operating costs, and a minimized impact on the environment though a smaller carbon footprint. Let us help you save some costs with maintenance, electricity, and give you a peace of mind that comes with clean air.

Did you know that it is estimated that poorly designed and maintained compressed air systems in the United States account for up to $3.2 billion in wasted utility payments every year? How much do you think your company is paying extra each month or each year?  There are a few ways that we at Sawyer can help you save some money.

First, have you ever had your compressed air system checked out for air leaks? Air leaks would be the largest component of wasted energy, even with the most efficient compressed air systems. Depending on pressure requirements and

energy costs, a single ¼” leak in a compressed air line can cost a facility from $2500.00 to more than $8000.00 per year. Locating and fixing leaks in a facility will show instant savings to a customer. Sawyer can perform a leak down test to your compressed lines. We have seen instant results from companies loosing 75% and once test is done they can be down to 25% leaks.

Energy costs have been on the rise over the years and may still be increasing so checking for leaks can save. Here is an example, a manufacturer was running at 50 horsepower compressor 24 hours a day at 3 cents per kWh; however, these costs have doubled everywhere in the last 5 years, increasing some areas to 8 cents per kWh or more. The annual costs to operate that compressor at 3 cents per kWh was $10,318.25. Today, that same compressor cost $27,515.50 to operate every year at 8 cents per kWh, or more than $68,000.00 over five years.

Call Sawyer and ask to speak with Paul or John O about possible rebates they can find from utility companies as they offer additional rebates or reduced rates when leaks are found and fixed. These incentives can further reduce manufacturing costs and benefit the environment through lower energy demands.

To calculate the cost of compressed air, use the following formula:


Cost ($/year)= motor hp x .746 x hours of operation (per year) x electric rate ($/kwh)/ motor efficiency