Don’t let profits leak into thin air

An Australian food manufacturer was literally blowing over $55,000 in wasted energy costs annually… and didn’t know it! The manufacturer believed the efficiency control and maintenance regime for its sizeable compressed air system was entirely adequate.

As a matter of energy-use review, the manufacturer called Southern Cross Compressors (Australia) Pty Ltd to carry out the thorough air audit.

Using the latest leak detection technology (UE Ultraprobe 9000), which detects and records the decibels at the natural frequencies of air leaks, accurate leak detection can be recorded from up to 10 m away from the probe. This ensures detection of even the smallest leaks throughout the compressed air system. While most leaks were easy to repair, according to Southern Cross Compressors, they would not have been discovered without the use of this advanced leak detection technology.

Using a calibrated chart, the detected sound level (dB(A)) then converted to a volume flow rate (m³/min), which in turn is converted to power (kW) to calculate annualised costs, determined on running hours and electrical supply costs. All leaks were individually tagged using colour codes based on severity and then photographed for a customised report.

The comprehensive, 50-page audit report, which was presented to the customer, included highly critical data such as: individual leak volume, equivalent power, annualised cost, equivalent CO₂ emissions as well as a photo of the colour-tagged leak. The report also provided a comprehensive summary of the potential savings opportunity, which has enabled the customer to make informed decisions and prioritise leak repairs based on severity, energy loss and repair costs.

Southern Cross technicians were able to find over 50 significant leaks with a total air volume well over 10 m³/min, representing an annualised wasted energy cost of approximately $55,000.

In today’s efficiency-driven age where energy costs are fundamental to business sustainability, this type of audit and reports advice can lead to significant cost savings. For the relatively low cost of the air audit, potential returns can far outweigh expense.

Originally published here.