Measure Before You Replace
Compressed air is one of the most expensive utilities in manufacturing. Yet many systems are upgraded, modified or replaced without first understanding how they actually perform.
At West Midlands Compressors Ltd, we believe decisions should be based on measured system performance rather than assumptions.
That is why we now offer compressed air data logging and performance audits, allowing us to analyse how a system behaves over time and identify hidden inefficiencies.
We record current, airflow and pressure to assess operating patterns, demand and supply performance. Energy and running-cost figures derived from current and compressor data are estimates, not directly measured kW or kWh.
What Is Compressed Air Data Logging?
Compressed air data logging is the process of monitoring system performance continuously over a period of time, typically between 7 and 14 days.
Specialised sensors are temporarily installed on the compressed air system to measure:
- Air flow demand
- System pressure
- Compressor electrical current
- Load and unload behaviour
- Pressure stability across the network
This data is then analysed to build a detailed profile of how the system operates during production hours, idle periods and shutdown times.
The result is a clear and objective understanding of how efficiently the compressed air system is performing.
Why Data Logging Is Important
Compressed air systems are frequently sized using assumptions rather than real demand.
Over time, production changes, new equipment is added and systems evolve. As a result, compressors may become oversized, inefficient or incorrectly controlled.
Measurement helps answer questions such as:
- How much air is actually being used
- Whether compressors are running efficiently
- How much energy is being wasted
- Whether pressure is higher than necessary
- How significant air leaks are
Data logging provides the evidence needed to optimise the system properly.
What We Measure During A Performance Audit
A typical compressed air performance study will analyse several key parameters.
Air Demand Profile
A flow meter measures the actual compressed air consumption across the monitoring period. This reveals peak demand, average demand and base load requirements.
System Pressure Stability
Pressure loggers monitor how stable the system pressure is and identify pressure drops within the network.
Compressor Current and Energy Estimates
Current logging helps identify operating patterns. WMC does not directly measure electrical power during these audits; estimates use suitable compressor data and stated assumptions.
Compressor Load Behaviour
By analysing compressor loading cycles, we can identify inefficient load/unload operation or poor control strategies.
Leak Load Estimation
Non-production airflow can help estimate avoidable demand after accounting for equipment and air-treatment functions that remain active. A separate leak survey locates individual leaks.
Interpreting Energy Estimates
Measured airflow can be compared with estimated energy consumption, provided the report identifies the calculation method and limitations. Directly measured specific energy requires suitable electrical energy measurement over the same period and a clearly defined system boundary.
Typical Problems Data Logging Reveals
Performance audits frequently identify issues such as:
- Oversized compressors
- Excessive system pressure
- Significant air leaks
- Artificial demand caused by high pressure
- Poor compressor control sequencing
- Pressure drops across filters and pipework
- Undersized or poorly designed distribution systems
Many of these problems can lead to substantial energy waste and reduced reliability.
Our Data Logging Process
West Midlands Compressors Ltd follows a structured approach when carrying out a compressed air performance audit.
1. Initial Site Review
We assess the compressor installation and identify suitable locations for monitoring equipment.
2. Installation of Data Loggers
Temporary sensors monitor airflow, pressure and compressor current at agreed measurement points.
3. Monitoring Period
The system is monitored continuously, typically for 7–14 days, to capture real operating conditions.
4. Data Analysis
Performance data is analysed using cloud-based monitoring software to identify trends and inefficiencies.
5. Detailed Performance Report
A structured report is produced summarising findings and recommendations for improvement.
Benefits Of A Compressed Air Performance Audit
A data-driven analysis can help businesses:
- Reduce compressed air energy costs
- Identify avoidable air demand for further investigation
- Improve compressor reliability
- Optimise system pressure
- Plan equipment upgrades correctly
- Avoid unnecessary compressor replacement
In many cases, significant energy savings can be achieved simply by optimising existing equipment.
Who Can Benefit From Data Logging?
Compressed air performance audits are particularly valuable for:
- Manufacturing facilities
- CNC machining workshops
- Laser cutting operations
- Food processing plants
- Automotive suppliers
- Packaging and plastics manufacturers
Any business where compressed air plays a significant role in production can benefit from understanding how their system performs.
Why Choose West Midlands Compressors Ltd
West Midlands Compressors Ltd specialises in the supply, installation and optimisation of industrial compressed air systems across the Midlands.
Our approach focuses on:
- Technical expertise and real-world experience
- Data-driven system design
- Energy efficiency and system optimisation
- Long-term reliability for industrial users
Rather than recommending equipment blindly, we prefer to measure system performance and design solutions based on real demand.
Book A Compressed Air Performance Audit
If you would like to understand how your compressed air system is really performing, West Midlands Compressors Ltd can carry out a professional performance audit using advanced monitoring equipment.
The study will provide clear insight into system demand, efficiency and potential areas for improvement.
To discuss a compressed air performance audit for your facility, contact our team today.
West Midlands Compressors Ltd
Industrial Compressed Air Specialists
0800 002 5131
www.wmcompressors.co.uk/contact
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