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Cutting Power Consumption in Half
Removing modulation and drastically improving efficiency
The Case
Fleetwood Air Equipment had been servicing this customers Sullair LS160-75H for many years when the customer began experiencing frequent downtime and recurring repair issues. During our assessment, we also identified that the facility was using an inefficient desiccant dryer, despite not requiring that level of air quality. The customer agreed to proceed with an Air Demand Analysis (ADA) to accurately determine the correct compressor size — ensuring the new unit would be properly matched for optimal operation, efficiency, and long-term reliability.
The Numbers Never Lie
The Air Demand Analysis revealed that the existing compressor was operating in a heavily modulating and highly inefficient state. Our findings showed the customer’s average air demand was only 78 CFM, with peak demand reaching 248 CFM.
The system’s specific power consumption was calculated at 59.47 kW per 100 CFM — a figure significantly higher than the ideal, which is typically in the low 20s for this horsepower range.
Additionally, we identified that removing the desiccant dryer would drastically reduce system demand, allowing us to lower the required compressor size from 75 HP to just 30 HP — unlocking substantial energy savings and improving overall efficiency.
The Solution
We installed two new Kaeser ASD 30 compressors along with an additional 800 gallons of storage capacity. The system upgrade also included new refrigerant dryers, line filters, and a system pressure regulator. This setup allowed the customer to fully leverage the benefits of high-pressure storage, regulating the system pressure down to match actual demand. As a result, the facility saw an estimated annual power cost savings of $25,000, along with a significantly more reliable and efficient compressed air system.
If you feel your compressed air system might be oversized, inefficient, or unreliable, please contact us today. We can start with a free system assessment and explore completing an Air Demand Analysis to determine exactly what your business needs and how much money can be saved.