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Latest article: Compressed air system design – how industry can save energy and costs

Compressed air system design – how industry can save energy and costs

Compressed air system design – how industry can save energy and costs

Teollinen paineilmajärjestelmä eli öljyvoideltu ruuvikompressoriasema jäähdytyskuivauksella Industrial compressed air system, i.e. oil-lubricated screw compressor station with refrigeration drying

Compressed air system design – expert summary

Compressed air system design means dimensioning and optimizing the air volume, pressure and quality of compressors, after-treatment (filtration and drying), compressed air piping and compressed air applications so that compressed air is produced as energy-efficiently and reliably as possible.

How much electricity does compressed air consume?

In industry, compressed air systems can use up to:

  • Typically 10–15 % of the facility's electricity, varies by industry.
  • A properly designed system can reduce energy consumption by up to 20–40 %.
  • According to a study conducted by SmartAir, the engineering and metalworking industry uses an average of 11 % of all electricity to produce and process compressed air.

What does compressed air system design mean?

Compressed air system design is a process that determines the sizing of compressors, the design of compressed air piping, drying and filtration solutions, and the measurement and verification of compressed air quality. In today's era (2026), this also means collecting data on key parameters and 24/7 monitoring with automatic alarms.

The aim is to ensure:

  • Production reliability
  • Minimal energy consumption
  • High quality compressed air
  • Long hardware life
  • Data-driven system usage
Paineilmajärjestelmä kompressorihuoneessa (kompressori, suodatus, kuivaus ja putkisto) Compressed air system in the compressor room (compressor, filtration, drying and piping)

Energy consumption of compressed air systems – key facts

  • Compressed air systems can use up to 10–15 % of the electricity in an industrial facility.
  • Up to 80% of the electricity used by the compressor is converted into heat.
  • Leaks in compressed air systems can cause up to 20–30 % of energy loss.
  • An energy-efficient compressed air system can reduce energy consumption by up to 20–40 %.

Energy consumption of compressed air systems in industry

Compressed air systems are one of the largest hidden energy consumers in industry. The problem is that the system often has significant losses: due to leaks, excessive pressure and suboptimal use, up to 20–30 % of compressed air produced can be wasted. Read more: Compressed air IoT.

Why is energy efficiency in a compressed air system important?

Compressed air production is one of the most energy-intensive processes in industry. A poorly designed system can cause high energy costs, pressure losses, production disruptions and quality problems.

Energy standards and ISO 50001

Modern industry is committed to reducing energy use. In practical terms, this means joining energy efficiency agreements or standards such as ISO 50001 energy management system.

Öljyvapaa keskipakoiskompressori, jossa nimellisteho 250 kW Oil-free centrifugal compressor with a rated power of 250 kW

Energy-efficient compressed air – where does the saving come from?

Compressor sizing

Correct sizing ensures that the system produces compressed air exactly as needed without unnecessary energy consumption.

Compressed air piping design

The diameter, length and structure of the pipeline affect pressure losses. A pressure loss of one bar (1 bar) causes 7 % of energy loss under the prevailing load situation.

Kuvan näkymätön paineilmavuoto aiheuttaa vuodessa 5788 kWh energiahukan The invisible compressed air leak in the picture causes 5788 kWh of energy loss per year

Compressor heat recovery

Up to 80% of the electricity used by the % compressor is converted into heat. This can be used for building heating, process heating or ventilation preheating.

Kompressorin lämmöntalteenotto Compressor heat recovery

Example calculation of compressed air system energy consumption

Suppose: Compressor 90 kW, operation 24/7, electricity price 0.10 €/kWh.

  • Annual energy consumption: 90 kW × 8760 h = 788,400 kWh
  • Annual cost: 788,400 kWh × €0.10 = €78,840
  • If energy efficiency is improved by 25 %, the savings are €19,710 per year.
Paineilman kastepisteen mittaus ja anturit Compressed air dew point measurement and sensors

SmartAir compressed air system design experts

Taito Mattila

Taito Mattila
Chief Designer

Jukka Mattila

Jukka Mattila
Mechanical and piping design

Sami Uusi-Erkkilä

Sami Uusi-Erkkilä
System sizing & IoT

How to optimize a compressed air system in industry

Optimization typically involves:

  • Defining the parameters to be monitored
  • Designation of a responsible person
  • Energy and compressed air consumption data collection
  • 24/7 system monitoring
  • Regular situation analysis and measures

Case: Compressed air station in a container – Juha Tuomainen Oy

Juha Tuomainen Oy faced the challenge of uncertain compressed air availability and high energy consumption. The solution was a modern compressed air station built into a shipping container.

Juha Tuomainen Oy, Aarne Tuomainen työstökoneet käyttävät paineilmaa

Results: approximately 40,000 kWh energy savings per year

Energy consumption was significantly reduced:

  • Old solution: approximately 17.4 kWh
  • New solution: about 8 kWh
  • This corresponds to approximately 40,000 kWh of energy savings per year.

Other benefits: Better production reliability, a cleaner solution, better working conditions and stable pressure.

Uusi paineilmakontti
Sami Uusi-Erkkilä SmartAir ja Aarne Tuomainen kättelevät “The collaboration went well and we are satisfied with the end result.” – Aarne Tuomainen

Frequently Asked Questions about Compressed Air Systems (FAQ)

Compressed air systems can typically use around 10–15 % of the electricity in an industrial facility. In a poorly optimized system, consumption can be significantly higher due to pressure losses and leaks.
Optimizing a compressed air system can often reduce energy consumption by 20–40 %. Savings are particularly achieved by repairing leaks, correct sizing, and optimizing use.
The most common losses arise from compressed air leaks, excessively high system pressure, poorly dimensioned piping and compressors, and inadequate monitoring.
Yes. Up to 80% of the electricity used by the % compressor is converted into heat that can be used for building heating, process heating or ventilation preheating.
It is a good idea to check the condition and energy efficiency at least every 1–2 years. Leak surveys and energy monitoring help identify issues in a timely manner.
A typical screw compressor consumes 7 kW / m3/min (at 7 bar,g pressure). For small machines, the value can be 8 kW and for larger ones even 6 kW.
For example, a leak with a Fluke LeakQ value of 7.0 (approximately 53 l/min) causes approximately 3200 kWh of energy loss per year. Large leaks are usually repaired immediately based on the sound.
The overall efficiency of compressed air is quite low: only about 10–20% of the electrical energy is converted into useful work. The rest is lost mainly as heat and losses.
In 24/7 operation, up to 80% of the life cycle costs can come from energy use. Maintenance and equipment investment typically make up the remaining 20%.
Sami-Uusi Erkkilä

Sami Uusi-Erkkilä

Managing director

040 776 8384
sami@smartair.fi

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