Energy & Efficiency

Elimination of Unnecessary Energy Waste

At DFP Compressed Air Technology we offer many services to assist in the elimination of unnecessary energy waste.

  • Air Compressors consume six percent of all energy produced globally. Compressed air is on the Department of Energy’s hot list.
  • At $.15 per KWh an air compressor running 24/7 will cost you $1000.00 per horsepower per year to operate. A poorly maintained
    compressor will cost you even more.
  • As an example, a 150-horsepower compressor running 24/7 @ $.15 per KWh will cost you $150,000.00 annually to operate.
  • Additionally, the same compressor poorly maintained or a mis-adjusted system could run you as much as $10,000.00 more
    annually to operate.

Maintaining your equipment will greatly reduce the cost of ownership.

Calculate Power Cost For An Air Compressor

Example: 200-hp compressor (which requires 215 bhp) that operates for 6800 hours annually. It is fully loaded 85% of the time (motor efficiency = .95) and unloaded the rest of the time (25% full-load bhp and motor efficiency = .90). The aggregate electric rate is $0.05/kWh.

Leak Audits

The majority of manufacturing facilities leak 20 to 40 percent of the air produced. A total combination of air leaks equaling 3/8″ will cost you more than $25,000.00. Many companies approach this problem by selling you an additional compressor or a larger replacement.

At Compressed Air Technology we will bring out our Ultra Sonic Leak detection equipment and give you the precise cubic feet you are losing and a quotation to repair them. On average we see an 8-month ROI.

We also offer a DIY solution. Rental leak detection devices are available or you can purchase your own Ultra Sonic Leak detector.


A system without adequate storage or properly controlled storage creates issues with upstream and downstream at the receiver.

On the supply side an air compressor needs enough storage to control the VFD correctly or the loading or unloading of the equipment. Limited storage can cause the compressors to fail prematurely.

On the demand side (plant side) a receiver is paramount in handling manufacturing anomalies. In many cases a flow control device should be installed on the discharge of the receiver to stabilize plant pressure and allow time or plant events and the replenishment of pressure in the tank. Installing a flow controller can reduce your energy cost and improve the plants air stability and manufacturing quality.

Machine Optimization

It’s not always necessary to add specialty equipment to improve energy efficiency. In most cases we can adjust and optimize the dynamics of your installed equipment to reduce your maintenance, improve reliability and lower energy costs.

Contact our Service department at (833) 307-5970 to send out a system optimization Technician.

Full Plant Air Audits

An air system is horribly inefficient. At best most systems are 10 to 15% efficient. This is due to the heat of compression and the displacement of that heat.

Because dynamics in a facility change continually, most plants should have a supply side (compressor room) and a demand side (plant floor) audit every two years. This will ensure your system is efficient, your equipment is operating correctly, and utilizing the air properly.

DFP Compressed Air Technology is ready to help your company’s bottom line.

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