You can prevent unnecessary compressed air production during weekends by setting up automatic shutdown of compressors through timers and pressure switches. Configure weekend schedules with customized pressure bands and use intelligent control systems that match compressed air production to actual demand. This saves up to 30% energy and significantly reduces wear on your equipment.
Why weekend compressed air production poses a problem
Compressed air compressors running unnecessarily during weekends cause energy waste and significantly increase your operational costs. Many industrial companies leave their compressed air systems running continuously, even when no production is taking place.
This problem arises because compressors are often set to weekday schedules without accounting for reduced demand during weekends. The consequences are immediately noticeable in your energy bill and the lifespan of your equipment.
Additionally, unnecessary compressed air production contributes to increased CO2 emissions and environmental burden. For heating installers and tank builders, this often means that customers face higher operational costs than necessary.
How does automatic shutdown of compressed air systems work?
Automatic shutdown of compressed air systems operates through intelligent control systems that monitor actual compressed air demand and control compressors accordingly. These systems use pressure switches, timers, and advanced control modules.
Modern control systems can accurately measure the flow being consumed and account for compressed air pressure in the piping system. This makes it possible to control compressors very precisely and minimize the difference between desired compressed air and switch-on pressure.
The systems communicate via digital and analog signals to monitor machine status. In a compressor park with multiple units, one controller can function as a master unit that coordinates start and stop commands for all connected compressors.
Which settings should I adjust for weekend mode?
For an effective weekend mode, you adjust pressure bands and configure time schedules that align with your actual production patterns. Begin by setting lower pressure bands during weekend hours.
Configure delay timers that prevent compressors from switching on and off unnecessarily during small pressure fluctuations. This significantly reduces wear and energy consumption.
Set up backup systems for processes that require compressed air even during weekends. Consider cooling systems, nitrogen generators, or other continuous processes that require minimal compressed air supply.
| Setting | Workday | Weekend |
|---|---|---|
| Switch-on pressure | 7.5 bar | 6.5 bar |
| Switch-off pressure | 8.5 bar | 7.5 bar |
| Delay timer | 30 seconds | 120 seconds |
What are the benefits of smart compressed air control?
Smart compressed air control delivers energy savings of up to 30% by running compressors only when there is actual demand for compressed air. This translates directly into lower energy costs.
The reduced equipment wear results in lower maintenance costs and longer lifespan of your compressors. Fewer start-stop cycles mean less mechanical stress on moving parts.
Intelligent control takes into account factors such as run-down time, power consumption at no load, and prohibited resonance frequencies. This makes your system not only more efficient but also more reliable.
For companies with multiple locations, smart control offers the possibility to centrally monitor and control compressors at different locations via network communication.
How do I check if my compressed air system works efficiently?
Check your compressed air system’s efficiency by monitoring compressed air consumption during different periods and comparing this with your production patterns. Use modern monitoring systems for continuous surveillance.
Detect leaks by measuring pressure losses when all compressed air consumers are switched off. A good system should maintain pressure stably for at least 15 minutes without compressor activity.
Monitor the switch-on and switch-off times of your compressors. Frequent short cycles indicate inefficient control or undersized pressure tanks. Long running times at low load point to oversized equipment.
Use touchscreen displays or software applications to gain real-time insight into machine statuses, alarm notifications, and energy consumption of individual compressors in your park.
Key action points for weekend compressed air optimization
Start by inventorying your actual compressed air needs during weekends and adjust your systems accordingly. Install automatic switching schedules that shut down compressors when there is no demand.
Invest in intelligent control systems that can coordinate multiple compressors and optimize energy consumption. These systems pay for themselves through lower energy costs and reduced maintenance.
Plan regular inspections of your compressed air system to detect leaks and optimize settings. Keep track of operating hours and analyze consumption patterns to identify further savings.
For more complex installations or when in doubt about optimal settings, professional support is recommended. We at Presscon are happy to help you implement efficient compressed air control that suits your specific situation and ensures sustainable energy savings.