Compressor Cost Savings Opportunities

Like all equipment, compressor units require a certain level of maintenance. However, compressor maintenance costs are relatively low relative to other costs, and further savings can be achieved through careful planning measures. The choice of maintenance level depends on the required reliability and performance of the compressed air installation.

01  Maintenance

Maintenance costs represent a small percentage of the total cost of ownership of a compressor unit. It depends on the overall planning of the compressor installation and the specific compressor and auxiliary equipment selected. When the compressor is operating in an automated manner, maintenance costs can be reduced if condition monitoring is combined with other functions and the entire compressor central facility is monitored. Annual maintenance costs for a compressor typically range between 5-10% of the machine’s investment value. The total maintenance budget is affected by the following factors:

- Compressor type                                - media quality

- Auxiliary equipment (dryers, filters, control          - Maintenance plan

and regulation equipment)                       - Selected security level

- Duty cycle loading/unloading                      - Energy recovery/cooling system                      

- Installation conditions                            - Utilization

02  Maintenance plan

By carefully planning compressor maintenance, maintenance costs can be predicted and the service life of machines and ancillary equipment can be extended. In addition, this can reduce the cost of repairing minor problems and reduce downtime. With the use of more professional electronic devices, many machines are equipped with diagnostic inspection instruments. This means parts can be better utilized and replaced only when really needed. When a part needs to be repaired, it can be detected early before damage occurs, thus avoiding subsequent damage and unnecessary downtime.

By purchasing after-sales service, employee service and genuine spare parts from the compressor manufacturer, the machine will be able to maintain high technical operating standards; in addition, the manufacturer may also make suggestions for modifications and adjustments during the service life of the machine based on new experience accumulated during maintenance. . Maintenance needs assessments can be conducted by specially trained technicians, as well as training of in-house frontline maintenance personnel. Routine inspections are best done by skilled in-house staff, who can hear and see things on site that remote monitoring devices cannot.

03  Auxiliary equipment

The compressor unit can be easily expanded by adding auxiliary equipment to improve air quality or monitor the system. However, auxiliary equipment also requires maintenance and will incur maintenance costs (such as filter replacement, desiccant replacement, adaptation to other equipment, and staff training, etc.). In addition, there are some secondary maintenance costs, such as distribution networks and production machines affected by compressed air quality, as well as the replacement costs of oil and filter elements. All of these costs must be evaluated when calculating the total cost of ownership to inform the decision to invest in a new compressor.