Reducing Energy Waste in Compressed Air Systems

Sector: Packaging Manufacturer – Midlands

The Challenge: Rising Energy Costs from Compressed Air

A Midlands-based packaging manufacturer was running multiple compressors to cover production demand. Rising electricity bills and fluctuating air supply indicated the system was inefficient. Management wanted clear data on usage and ways to reduce waste.

Our Data Logging Approach

West Midlands Compressors Ltd conducted a 7-day data logging survey to capture the factory’s actual compressed air demand. The results showed: • Oversized compressors consuming excess energy. • Noticeable air leaks across the system. • Inefficient dryer and filtration setup.

System Optimisation and Right-Sized Compressor Solution

• Recommended a Mattei Maxima 30 compressor, correctly sized to match the factory’s demand profile. • Reconfigured the dryer and filters for optimal efficiency. • Introduced a leak detection and preventative maintenance programme.

The Results: 22% Energy Cost Reduction

• 22% reduction in compressed air energy costs. • Improved reliability with fewer pressure drops. • Greater visibility of system performance for future planning.

Customer Feedback

“The data logging made it clear where we were wasting money. The new system is saving us thousands each year while giving us more confidence in our production.” – Operations Manager

How West Midlands Compressors Can Help Your Business?

West Midlands Compressors Ltd
Unit 3B, Church Farm, Claines, Worcester, WR3 7RL
■ 01905 347341
■ enquiries@wmcompressors.co.uk
■ www.wmcompressors.co.uk