Creemers Compressors on compressed air as a hidden bulk consumer: how much money do you unknowingly blow away every day?

In many businesses, the compressed air compressor runs unnoticed day and night. From auto workshops to industrial production lines, compressed air is indispensable. But in practice, it is also one of the least visible cost items. Leaks, mismatched compressors and outdated piping create structural waste.

"Thousands of euros disappear every year without anyone noticing," says Daniel Walstock of Creemers Compressors. The system works, so it's not looked at. Until we start measuring."

Little awareness

Daniël has worked in the world of compressed air for many years. From his role as Technical Advisor, he visits companies weekly to review systems, give advice and provide insight into energy savings. "I'm not a typical salesman," he says. "My strength is in thinking with the customer. Not pushing for sales, but giving honest advice on what really suits their situation."

And that's necessary. Because compressed air is a major hidden consumer in many companies. Costs remain under the radar, while energy consumption is high. "People don't realize what a little air costs," says Daniel. "I once visited a customer where compressed air consumption was much higher in the summer. As it turned out, employees were cooling themselves with an air hose under their overalls."

The culprit: no-load consumption

Waste often occurs from small, seemingly innocuous things: a leaking hose, a worn coupling, a porous pipe ... "It seems minimal, but the costs can add up quickly. If you also leave the compressor on at night or on weekends, a lot of money is lost just like that."

One of the biggest culprits with rotary screw compressors is no-load consumption. "Many companies are still running with an old-fashioned screw compressor that, even when there is no demand, continues to run after-hours. That costs up to 40 percent of the rated power, with no compressed air in return."

Prevent waste and overload

Daniel says the solution lies in awareness combined with technology. "A variable speed drive ensures that a compressor delivers exactly the right amount of air of the desired pressure - no more, no less. This prevents waste, as well as overloading your power connection. And the latter is increasingly a bottleneck these days."

Daniel sees companies struggling with peak loads. "Some customers just can't get their grid connection from grid operators anymore. Then suddenly there's a diesel generator humming outside. That's anything but sustainable. Whereas with the right configuration and sizing, you can prevent a lot of grid load."

Airsavers and leakage prevention

Creemers supplies, among other things, Airsavers: smart valves that prevent unnecessary leakage of compressed air. Daniel explains: "They don't save air, but ensure that you have no leakage losses outside working hours. In addition, they slowly seal the pipes, which prevents shock - and that in turn prevents new leaks."

But the real gain is often in detecting and fixing existing leaks. "With an ultrasonic meter, we can mark exactly where things are going wrong. That's really customized work," says Daniel." Sometimes the pipework is thirty years old and you can hardly reach it. Then we have to find other solutions."

Measurement is knowledge

To properly identify waste, Creemers works with data logging and energy measurements. "We place a logger on the compressor, measure for a week and analyze the consumption down to the detail level. That way we know exactly what the actual consumption is, at any time of the day. And then you often see that the current compressor is much too big or inefficient for what is needed."

Daniel says this is more common than you think. "Companies change: machines are replaced, processes changed, but the compressor remains the same. I regularly come across installations that have been running for 25 years. Once appropriate, but now completely out of balance."

Sincere advice over quick wins

Creemers Compressors is in a displacement market, in which many suppliers compete on price. Yet the company deliberately chooses a different course. "We focus on quality," explains Daniel. "The right machine in the right place, to ensure longevity and reliability."

He emphasizes that purchase costs are only a small part of the total picture. "The investment in a compressor is about 20% of the total cost. About 70% goes on energy consumption and 10% on maintenance. Then it makes little sense to save on the purchase if you pay too much for it for years afterwards. We think beyond the purchase. The Total Cost of Ownership counts."

Tips for Entrepreneurs

What can you do as an entrepreneur yourself? "Walk around your workplace. Have a measurement done. See if your compressor still fits your production process. And get good advice before you buy just anything."

SMEs in particular tend to buy used compressors. "That seems attractive in terms of price, but rarely fits. Then you run way too big, resulting in high energy costs. Or you buy an installation that is already quite worn out. Within a year it breaks down - and then you're still more expensive."

This article is part of a triptych on energy efficient business, in cooperation with Creemers Compressors, WellColl and Draline.