Delivering Measurable Savings Through Data-Driven Compressed Air Optimisation
Project Overview
Rowan Precision, a manufacturing company based in Birmingham, undertook a major energy efficiency programme as part of its commitment to reducing carbon emissions and progressing towards net zero targets.
As part of this initiative, West Midlands Compressors Ltd supported the compressed air element of the project, focusing on reducing energy consumption through accurate system analysis and optimisation.
The Challenge
Compressed air systems are often one of the largest energy users in manufacturing environments.
Initial observations suggested:
- The existing compressor may be oversized for actual demand
- There were energy losses within the compressed air network
- Overall system efficiency could be significantly improved
The installed HPC ASK40 appeared to be operating inefficiently, but accurate demand data was required before making any changes.
Our Approach
✔ Data Logging & Demand Analysis
We installed data logging equipment to monitor the system over a defined period.
This allowed us to:
- Accurately measure air demand and load profile
- Identify inefficiencies and excessive unloaded running
- Confirm that the existing compressor was oversized
All decisions were based on real operational data, ensuring the correct solution was implemented.
✔ Correctly Sized Compressor Installation
Based on the data collected, the existing unit was replaced with a Mattei Blade 18i Plus.
By downsizing to a correctly matched compressor, we achieved:
- Improved efficiency under actual operating conditions
- Reduced unloaded running time
- Lower energy consumption
✔ Leak Detection & Repair
A full inspection of the compressed air network identified multiple air leaks.
All leaks were repaired, resulting in:
- Reduced compressed air wastage
- Lower system demand
- Improved overall system performance
✔ System Optimisation
Following installation and repairs, the system was reviewed and adjusted to ensure optimal performance across all operating conditions.
The Results
The wider energy efficiency programme delivered:
- 104,856 kWh annual energy reduction
- 23.63 tonnes CO₂e saved per year
The compressed air improvements — including data-led downsizing and leak reduction — played a role in achieving these results.
Why This Matters
This project highlights a common issue across many manufacturing sites:
👉 Compressed air systems are frequently oversized and inefficient
Without proper analysis:
- Energy is wasted through incorrect equipment selection
- Air leaks increase demand and running costs
- Systems operate far below optimal efficiency
A data-driven approach allows businesses to:
- Accurately match equipment to demand
- Reduce energy consumption
- Improve reliability and performance
- Support sustainability and net zero objectives
Conclusion
By combining data logging, correct compressor sizing, and leak elimination, Rowan Precision achieved measurable improvements in both energy efficiency and carbon reduction.
West Midlands Compressors Ltd is proud to support manufacturers across Birmingham and the wider Midlands with data-driven compressed air solutions that deliver real, measurable results.
Not sure if your compressor is correctly sized?
We offer:
- Data logging & air demand analysis
- Leak detection surveys
- System optimisation and upgrades
Blade 18i Plus
Blade 18i Plus
Head Office
Unit 3b Church Farm, Cornmeadow Lane, Claines, Worcester, WR3 7RL
Call Us 24/7
0800 002 5131
EMAIL US
enquiries@wmcompressors.co.uk
