Economic analysis for a hydraulic component manufacturer

This economic analysis was carried out at the customer's request. Previous analyses in 2021 and 2024 made it possible to compare key parameters and their development.

In 2021, the main economic indicator of compressed air generation (specific energy consumption for compressing 1 m³ of air) was assessed at 0.139 kWh/m³. In 2024, the measured value was 0.131 kWh/m³. This seemingly small 6% improvement actually represents savings of approximately CZK 235,000 per year. Over a compressor room service life of 10 years, this covers the cost of replacing all the machines.

The improvement came from replacing the machines and adjusting their controls better than in 2021. However, the analysis found potential for further substantial savings by optimising control, for example through master control or a better cascade setup to minimise unloaded running of variable-speed compressors. This potential was around 13% of costs, or approximately CZK 440,000 in electricity costs. Including reduced maintenance needs and machine wear, total savings could reach CZK 480,000 per year.

Another valuable outcome of the analysis was determining the total leakage volume, followed by ultrasonic detection of the individual leak points.

Total leakage could be read from the air consumption chart during a complete production shutdown while the compressors were still running. The figure was 55 L/s, equivalent to unnecessary additional costs of CZK 952,000 per year.

This shows that even a modernised compressor room with relatively new machines can generate air very inefficiently. Removing leaks can also reduce air consumption throughout the plant.

In this case, the total savings potential was 39%, or CZK 1,432,000 per year.