The common pitfalls

These systems are among the most inefficient utilities on industrial sites. Compressed air in particular can consume 10-30% of site electricity, with 80-90% of input energy wasted as heat and a further 20-30% lost through leaks in typical unaudited plants. Pumps and fans are routinely oversized, throttled, or run at constant speed regardless of demand. Inappropriate end uses such as blowing, cooling and vacuum, and poor pressure management, compound the waste. Most sites lack ongoing monitoring, so the cost remains invisible until a major failure or capital request appears.

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