Energy Reduction

Most compressed air systems are wasting 20–30% of their energy output

Compressed air accounts for 10–30% of industrial electricity consumption in a typical manufacturing facility — and in most facilities, a significant proportion of that is being wasted. Air leaks, compressors running unloaded, working pressure set higher than necessary, no heat recovery — these are common, fixable problems that show up on your energy bill every month.

J&J Air Systems carry out compressed air energy audits and advise on practical improvements with clear payback periods. We’re not selling a product — we’re identifying where the waste is and giving you the options to address it.

Compressed air audits and leak detection

We use data logging and ultrasonic detection equipment to measure your system properly:

  • Locate and quantify air leaks across the distribution system — mapped and costed
  • Measure actual consumption vs compressor output
  • Identify whether working pressure is higher than your applications actually need
  • Assess compressor utilisation — are you running a fixed-speed machine at partial load most of the day?
  • Identify periods of high unloaded running where energy is being consumed but no useful air produced

You get a written report with prioritised recommendations and an estimated energy saving for each action — so you can make informed decisions about what to fix and in what order.

Variable speed drive (VSD) compressors

A fixed-speed compressor runs at full speed regardless of demand, venting energy when air isn’t needed. A VSD compressor adjusts its motor speed to match actual demand — producing only what’s required at any moment. In applications with variable demand (most real-world applications), a VSD typically reduces energy consumption by 20–50% compared to a fixed-speed machine of equivalent capacity. We can model the payback for your specific usage profile.

Heat recovery

Up to 94% of the electrical energy input to an air compressor is converted to heat. This is usually wasted to atmosphere through the cooling system. Heat recovery systems capture this energy and redirect it for space heating or process use — offsetting heating energy costs and significantly improving the overall economics of your compressed air system.

Where to start

Tell us your compressor setup, approximate running hours and electricity rate. We can give you a rough indication of whether there’s a material saving available before committing to a formal audit.

Call: 0800 027 8442 | Email: [email protected]