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Like most companies, yours probably is always looking for ways to save money so that you can invest it elsewhere. Your compressed air system probably has the solution waiting for you.

Compressed air systems, your most expensive utility, often have the ability to produce vast savings in electrical costs following an Air Power USA air system audit. Not only does "found money" result, but productivity and quality also improve.

How much savings can be extracted from your compressed air system? To establish your estimated annual electrical bill to produce compressed air, use this formula:


PC = HP x .746 ÷ ME x BPR x Hours

PC
 = Annual Power Cost
BHP
 = Total “on-line” horsepower in air compressors over a given time (BHP, which equals shaft HP)
X .746
 = Converts shaft HP to kW
÷ ME
 = Motor efficiency – convert shaft HP to input kW (for average plant use .9)
BPR
 = Blended Power – add up last 12 months of electric bill dollars.
Divide by time (12 months) equals total kWh (= $.00 kWh)
Hours
 = Total hours per year each total HP is run:
1 shift / 5 days per week = 2080 hours/year
2 shifts / 5 days per week = 4160 hours/year
3 shifts / 5 days per week = 6240 hours/year
Weekends = 2520 hours/year


Calculation example:

(2) 250HP compressors / 3 shifts / 5 days per week

Run 1 compressor on weekends during non production

Power rate = $.06 kWh
Production Air (weekdays)
PC =
(500HP)(.746)(.06)(6240)
.90
PC
 = $155,168/year
Non-Production Air (weekends)
PC =
(250HP)(.746)(.96)(2520)
.90
PC = $31,332/year
Total Annual Electrical Energy Cost to run air system
$186,500/year
Average Electrical Savings
 = $40,000 to $60,000/year
Average Cost of Optimization Audit = $5,000 to $15,000 *


* Cost depends on time and expenses. We have reviewed many smaller plants for $2,500 to $3,500 and have handled major products up to $150,000 (savings $1,000,000/year). It is very rare when any single manufacturing plant exceeds $15,000.

To receive a free estimate for the work and potential savings of a compressed air system audit, or for a firm quotation, contact us.


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Air Power USA Inc. | P.O. Box 292 | Pickerington, OH 43147 | Ph: 740.862.4112 | Fax: 740.862.8464
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