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The Value of an Audit


  • Reduce Operating Costs
  • Improve Productivity
  • Avoid Capital Loss
  • Manage your Air System

Read on to find out how!

Operating Cost Reductions – In most systems, 20-50% of the operating costs can be knocked out while improving the performance and quality of the air.

Example: One plant had multiple compressors distributed throughout the facility trying to feed the same system. The only problem was that they couldn’t get the compressors to stop fighting each other. By fixing some point of use problems, improving some piping and operating the compressors more effectively, operating costs will be drop $190,000 per year (29%) turning off several compressors permanently with a 16 month payback.

Example: A Client had switched over a delicate process to nitrogen as it continually gummed up due to air system contamination. The application consisted of seven machines operating at 1.5 cfm each. That little decision increased the cost of operation from $1600 per year to $16,000. The study showed that compressed air cost them $59,000 per year. Their opportunity on the air side was $27,000 (46%) and the nitrogen was $29,000. In essence, the project will basically save almost the entire operating cost of the compressed air system. Payback is 14 months.

Productivity – Variations in air quality and pressure impact production processes. You demand repeatable performance in just about every other subsystem in your manufacturing process, why not demand it here too? You don’t have to accept “that’s just the way our air system is”.

Example: One client was about to invest $150,000 in compressors, dryers and filters because part of the plant had serious pressure problems. On the surface, certainly made sense and the solution would have solved the problem. In reality, the problem wasn’t capacity but rather it was a pressure drop problem due to a broken gate valve, slightly undersized piping, large demand events robbing the application, old in line separators and a tank that had filled up with water. This particular problem was solvable for under $10,000 with no increase in operating costs. New compressors are not the answer for most productivity problems.

Capital Avoidance – Most systems have excess capacity. Why not use that capacity and get the most out of your existing equipment before you spend additional dollars on equipment and installation services. Come to think of it, won’t that additional equipment add to your operating cost to? Unless it’s integrated correctly, it probably will.

Example: Another plant was adding compressors to their five unit system every time additional load was added to their process. By the time we worked on their system, they had added six compressors with all the tanks, dryers and filters. The audit determined that the entire system could have been run on the original five compressors. Operating cost reduction was just under $200,000 with a 13 month payback.

Information to Manage By – Most companies have a pretty good idea about some of the things that are happening in the air system. Do you know everything that happens in the air system? What about second shift or the weekend load? Most systems are designed for first shift and then operate by some kind of default during second shift. In addition, we find that an awful lot of production machinery doesn’t operate quite the way you think it might.

Example: One client wanted to boost pressure from the existing 75-85 psi to a 110 psi to make the process work better. There was only one problem. We discovered the process was actually operating at 60 psi. Raising the pressure in the entire plant would have increased their operating costs while not improving their process.

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