Calculating the total cost of ownership of compressed air requires a comprehensive analysis of all cost items over the complete lifespan of your system. You calculate the TCO by adding up acquisition costs, installation costs, energy costs, maintenance costs and operational expenses over typically 10 years. Energy costs often represent 70-80% of the total costs.
Why is calculating total cost of ownership of compressed air important for your business?
Calculating total compressed air ownership costs gives you insight into the actual financial impact of your compressed air system. Many companies focus only on the purchase price, but this represents only a small part of the total costs.
The energy costs of compressed air compressors can exceed the purchase price within a few years. A cheap compressor with high energy costs quickly becomes more expensive than a more efficient machine with higher acquisition costs.
By including all cost components in your calculation, you can make better investment decisions. This helps you select systems that are most cost-effective in the long term for your specific application.
What are the main cost components of compressed air ownership?
The compressed air cost analysis consists of various main categories that together determine the total cost of ownership. Each component has a different impact on your total expenses.
Acquisition costs include the compressor, dryers, filters, piping and control systems. Modern control systems can significantly improve efficiency by precisely matching compressors to actual demand.
Installation costs include assembly, electrical connections, piping and commissioning. Energy costs typically form the largest part of the TCO and depend on the power, operating time and efficiency of your compressed air generation system.
| Cost Category | Percentage of TCO | Main Factors |
|---|---|---|
| Energy costs | 70-80% | Power, operating time, efficiency |
| Maintenance costs | 10-15% | Preventive maintenance, repairs |
| Acquisition costs | 10-15% | Compressor, auxiliary equipment |
| Installation costs | 3-8% | Assembly, piping |
How do you calculate the energy costs of your compressed air system?
Calculating compressed air energy costs begins with determining the actual power of your compressor under different load conditions. The nominal power does not always reflect the actual consumption.
Use this formula for annual energy costs: Power (kW) × Operating hours per year × Load factor × Electricity rate (€/kWh). The load factor varies between 0.7 and 1.0, depending on how intensively you use the system.
Modern control systems can significantly reduce energy consumption by precisely matching compressors to actual compressed air needs. This reduces the difference between desired compressed air pressure and switch-on pressure.
Measure your actual compressed air consumption during different periods to get an accurate picture. Seasonal variations and production peaks significantly influence energy consumption.
Which maintenance costs should you include in your TCO calculation?
The compressed air maintenance costs consist of preventive maintenance, unplanned maintenance and replacement of consumables. Preventive maintenance prevents costly breakdowns and extends the lifespan of your system.
Regular replacement of air filters, oil filters and oil keeps your compressor efficient. Dirty filters increase energy consumption and can lead to premature wear of components.
Plan major maintenance sessions such as overhauls and replacement of wear parts. These costs vary per compressor type and operating conditions. Oil-free compressors have different maintenance needs than oil-lubricated systems.
Account for service costs for specialist work. You cannot perform all maintenance yourself, especially with more complex systems with advanced control technology.
How do you make a realistic 10-year cost forecast for compressed air?
A reliable compressed air TCO forecast accounts for inflation, efficiency degradation and planned replacements. Energy prices can fluctuate considerably over a 10-year period.
Plan major maintenance interventions after 5-7 years, depending on the compressor type and operating conditions. These interventions can cost 15-25% of the purchase price but significantly extend the lifespan.
Calculate efficiency loss over time. Compressors gradually lose efficiency through wear, resulting in higher energy costs. Good maintenance minimizes this loss.
Account for changing production needs. Expansion of your business may require additional compressed air capacity, which affects your total cost picture.
Key insights for smart compressed air investment decisions
Successful compressor cost optimization begins with a thorough analysis of your actual compressed air needs. Over-sizing leads to unnecessary costs, while under-sizing can cause production disruptions.
Invest in modern control technology that precisely matches compressors to actual demand. These systems can reduce energy consumption by 10-30% by preventing unnecessary idling.
Choose reliable suppliers who provide complete support throughout the lifespan of your system. Good service and quick availability of parts prevent costly production downtime.
At Presscon we help you create a comprehensive TCO analysis for your specific situation. Our experience with various industries enables us to make realistic cost forecasts and advise the most suitable system for your application. Contact our team to discuss your compressed air requirements.