Compressed Air Energy saving Evaluation - Specialty chemicals & adhesives

Goals

• Identify and quantify compressed air leaks throughout various departments and systems.
• Establish a data-driven repair strategy based on accurate measurements.
• Reduce energy waste and associated costs from compressed air leaks.
• Improve system reliability and operational efficiency through targeted repairs.

Challenges

• Widespread leakage: 255 leak points were found across the facility, totalling 250.737 CFM of wasted air and an estimated annual cost of $46,257.
• Leak sources were diverse, with 49% from thread connections, 16% from tube connections, and 10% from actuators.
• Poor system layout: Randomized air connection routing led to excessive hoses and unnecessary leak points.
• Old leak tags still present, showing unresolved historic issues and highlighting the absence of a formal leak repair program.

Discovered Potentials

• Energy savings opportunity of over $46,000 annually through leak repair alone.
• Opportunity to implement a structured leak repair and follow-up process, including tracking and validation.
• Potential to reduce leak risks by redesigning the air connection layout and minimizing hose usage.
• Audible leak detection can be integrated into regular maintenance routines—50% of leaks were large enough to be heard without instruments.