Creemers Compressors on Compressed Air as a Hidden Major Consumer

In many companies, the compressed air compressor runs unnoticed day and night. From auto repair shops to industrial production lines, compressed air is indispensable. But in practice, it’s also one of the least visible cost items. Leaks, poorly tuned compressors, and outdated piping lead to chronic waste.

“Thousands of euros disappear every year without anyone noticing,” says Daniël Walstock of Creemers Compressors. “The system works, so no one pays attention to it. Until we start measuring it.”

Little awareness

Daniël has been working in the compressed air industry for years. In his role as Technical Advisor, he visits companies every week to assess systems, provide advice, and highlight energy-saving opportunities. “I’m not your typical salesperson,” he says. “My strength lies in thinking alongside the customer. I don’t push for sales; instead, I give honest advice on what truly suits their situation.”

And that’s necessary. Because compressed air is a hidden major consumer of energy in many companies. The costs stay under the radar, even though energy consumption is high. “People don’t realize how much a little air costs,” says Daniël. “I once visited a client where compressed air consumption was much higher in the summer. What did I find out? Employees were cooling off by spraying air under their coveralls.”

The culprit: idle power consumption

Waste often results from small, seemingly harmless things: a leaky hose, a worn-out coupling, a porous pipe… “It may seem minor, but the costs can add up quickly. If you leave the compressor running at night or on the weekend, you’ll end up losing a lot of money.”

One of the biggest culprits with screw compressors is no-load consumption. “Many companies still use outdated screw compressors that continue to run even when there is no demand. That consumes up to 40% of the rated power without providing any compressed air in return.”

Prevent Waste and Overload
 

According to Daniël, the solution lies in raising awareness combined with technology. “A variable-frequency drive ensures that a compressor delivers exactly the right amount of air at the desired pressure—no more, no less. This prevents waste, but also prevents overloading your electrical connection. And the latter is increasingly becoming a bottleneck these days.”

Daniël observes that companies are struggling with peak loads. “Some customers simply can’t get their grid connections approved by grid operators anymore. Then suddenly there’s a diesel generator humming away outside. That’s anything but sustainable. Whereas with the right configuration and sizing, you can prevent a lot of grid strain.”

Airsavers and Leak Prevention
 

Among other products, Creemers supplies Airsavers: smart valves that prevent compressed air from leaking unnecessarily. Daniël explains: “They don’t actually save air, but they ensure you don’t have any leakage losses outside of working hours. In addition, they shut off the lines slowly, which prevents pressure surges—and that, in turn, prevents new leaks.”

But the real benefit often lies in detecting and repairing existing leaks. “With an ultrasonic meter, we can pinpoint exactly where the problem lies. That’s truly custom work,” says Daniël. “Sometimes the piping is thirty years old and barely accessible. In those cases, we have to find other solutions.”

To measure is to know
 

To accurately identify waste, Creemers uses data logging and energy measurements. “We install a data logger on the compressor, take measurements for a week, and analyze the consumption in detail. That way, we know exactly what the actual consumption is at any given moment of the day. And then you often see that the current compressor is much too large or inefficient for what’s actually needed.”

According to Daniël, this happens more often than you might think. “Companies change: machines are replaced, processes are adjusted, but the compressor stays the same. I regularly come across systems that have been running for 25 years. They were once suitable, but are now completely out of balance.”