Compressed air cost analysis statistics

Compressed air is a form of energy whose production costs vary widely.

For straightforward comparisons, the usual measure is energy consumed per Nm³ of air produced, expressed in kWh/m³ or J/litre. However, these figures are not easy for many non-specialists to interpret.

We therefore more often express costs in CZK/m³, multiplying kWh by the usual or average electricity price.

The following table compares the frequency of cost levels per Nm³ based on analyses of real manufacturing plants in 2019 and 2020. These prices include equipment purchase and servicing costs, which account for only around 20–25%. The wide range reflects how well the compressors match air demand. The cause is often not obsolete equipment but errors in the original station design, which we also frequently encounter in new installations. Other common causes are production expansion without corresponding compressor changes, or gradual or sudden changes in production volume and therefore air consumption.

The statistics show that around half of the companies fall in the excellent or acceptable range, yet even these often have scope to save 30–50% of energy costs. Above CZK 0.6/m³ the equipment is evidently obsolete, incorrectly specified or poorly operated. In such cases, investment in station refurbishment, equipment modifications, new compressors or the hire of different machines can offer a very attractive payback.