The Hidden Power of Compressed Air in Food Manufacturing
The Hidden Power of Compressed Air in Food Manufacturing
Introduction
At Emergent Energy, we understand that compressed air is both a critical asset and a hidden cost in food manufacturing. From sealing in the freshness of coffee beans and packaged goods to powering pneumatic equipment, compressed air is indispensable. Yet inefficiencies—such as leaks, improper compressor management, and unnecessary operation during downtime—can drive up energy costs, compromise product quality, and hinder sustainability efforts.
The solution lies in real-time energy monitoring and optimization. By leveraging advanced cloud-based technology, we help manufacturers uncover and address these hidden inefficiencies, delivering measurable energy savings and operational improvements.
The Role of Compressed Air in Food Manufacturing
Compressed air is as essential as water, gas, and electricity in food production. It’s used for:
- Nitrogen generation
- Vacuum and dust collection filtration management
- Operating pneumatic equipment
However, food manufacturers face significant challenges:
- Strict Food Safety Regulations - Air must remain clean, dry, and contaminant-free to comply with FDA and ISO 8573-1 standards.
- High Energy Dependency - Compressed air can account for 30–50% of a facility’s total electrical energy usage.
- Inefficiencies That Drain Resources - Issues like undetected leaks, pressure fluctuations, and inefficient compressor sequencing can lead to substantial energy waste and increased operating costs.
Common Inefficiencies and Our Approach
1. Leaks – The Silent Spoiler of Efficiency
Up to 50% of compressed air can be lost through small, undetected leaks. Even minor leaks force compressors to work harder, while reducing productive air usage, which not only increases energy costs but reduces available system capacity as a growing portion of the system is being consumed by leak load rather than process load.
Our Approach:
We use advanced real-time compressed air flow monitoring to detect system leak load and pinpoint point of use air demand, enabling prompt repairs that prevent energy loss and compressed air capacity allocations to specific processes.
2. Short Cycling and Inefficient Compressor Management
Improper sequencing of compressors often leads to short cycling. This is especially prevalent on systems that operate with 3 or more compressors with insufficient air storage. A high capacity (multi-air compressor) system without sufficient storage will likely face rapid system cycling as spikes in air demand will cause system pressure drops. Since the air compressors are typically staged based on system pressure, a sudden pressure drop will cause frequent starts and stops.
Our Approach:
By employing smart electric and compressed air monitoring tools, we optimize compressor staging and stabilize system pressure to ensure reliable, efficient operations.
3. Air Misuse and Downtime Waste
Many facilities continue running their compressed air systems 24/7—even during non-production hours—leading to unnecessary energy consumption. Capacity management during down days will help to ensure the correct compressor mix is used during the peak demand and low demand hours of operation.
Our Approach:
Through continuous data analysis, we identify inefficient usage patterns and recommend operational adjustments to reduce energy use by right sizing the air compressor for the demand on the system.
Inside the Panoramic Power Dashboard for Compressed Air
Real-time monitoring is the key to transforming compressed air inefficiencies into measurable savings. With Panoramic Power’s cloud-based dashboard, manufacturers gain complete visibility into their system’s performance. Key metrics include:
Leak Detection:Real-time compressed air flow measurements on both supply and demand points. Supply headers should be monitored to measure compressed air generation pressure and flow characteristics during peak and non-peak periods. System leak loads will be reflected on collected data during down days while pinpointing leaks at point of use to ensure prompt intervention.
Figure 1 – Leak load management during off hours of operations. Identifying leak load air demand.
Compressor Cycling Patterns:
Compressor short cycling is a costly operational practice. Air compressor service maintenance cycles and life cycle ratings are typically based on run hours, but when a compressed air system short cycles, the system’s oil pumps, motor starters, electronics and various mechanical components start and stop multiple times per hour. Although the total run hours might be low, the short cycling will reduce the system’s operational life significantly.
Monitoring compressor start/stop cycles can identify and reduce short cycling, leading to improved energy efficiency, reduced system run hours and improve system longevity.
Figure 2 – System Short Cycling of (Orange). Leverage compressed air storage and proper pressure band settings to reduce system starts / stops.
● Air Pressure and Dew Point Monitoring:
Continuous pressure tracking ensures the system operates within optimal parameters, preventing performance issues from air treatment systems while reducing system short cycling. Many facilities utilize pressure gauges that are installed onto storage tanks. These gauges provide an instantaneous reading but provide little guidance on issues when they come up. We recommend integrating inline sensors to pair sensor data with compressor KW cycling data against air flow data to evaluate the system’s overall health.
These various metrics (KW Input, system pressure and dew point, air flow at main headers and point of use) integrate into actionable insights, allowing sustainability managers and plant operators to optimize performance, reduce waste, and document savings—all in real-time.
Case Study: How Lavazza Reduced Compressed Air Costs
At Lavazza’s West Chester, Pennsylvania facility, compressed air accounted for 37% of total energy usage. Recognizing the urgency to reduce this cost, Lavazza partnered with Emergent Energy and leveraged Panoramic Power’s real-time monitoring technology—backed by PECO’s incentive program—to address these challenges.
The Solution
Together, Emergent Energy implemented several key measures at LaVazza.
- Leak Detection and Repair - Rapid identification and repair of leaks to plug major energy drains.
- Identified pressure drops within the distribution system - Minimizing pressure drops and implemented a production area ring main to high air consumption equipment.
- Eco-mode Settings - Configuring compressors and nitrogen generators to shut off during low-demand periods, thus reducing unnecessary purge cycles and frequent system cycling; reducing energy consumption.
The Results
- Annual Energy Savings: Approximately 2.5 million kWh
- Cost Savings: An estimated $150,905 per year
- Project Cost: $200,000 – fully offset by $250,000 in PECO incentives
- ROI: The project effectively paid for itself through the incentive program
Reflecting on the project, Kevin Wong, General Manager of Emergent Energy explained:
“There are so many run-hours on a compressed air system like this, that even very minor changes can have huge impacts on energy use.”
Lavazza’s Manufacturing Engineer, Josh Miller, added:
“It was a huge opportunity for Lavazza to be more responsible with our energy use, and also just reduce our monthly spend on electricity.”
This case study clearly demonstrates how targeted system upgrades, informed by real-time monitoring, can transform compressed air from a hidden expense into a strategic asset.
The Future of Compressed Air Optimization
As real-time energy and carbon monitoring become increasingly integral to operations, manufacturers who invest in these technologies will gain a competitive edge. Not only will they lower operating costs, but they will also enhance sustainability and more effectively meet stringent food safety requirements.
Conclusion: A Smart Investment for the Future
Investing in real-time compressed air monitoring isn’t just about cutting costs—it’s about building a more efficient, sustainable, and reliable production environment. With smart analytics from Panoramic Power powering our solutions, we help manufacturers turn compressed air from an invisible expense into a measurable competitive advantage.
Real-time monitoring helps manufacturers cut energy costs, delivering significant annual savings.
Contact Emergent Energy today to learn how Panoramic Power’s Energy Intelligence Solutions can deliver measurable savings for your facility.
About the Author
Kevin Kai Wong is the General Manager at Emergent Energy Solutions and a Panoramic Power partner who serves clients in the USA. With over 20 years of experience delivering integrated energy solutions, Kevin combines technical expertise with a practical, results-driven approach to help organizations achieve emissions reductions and operational efficiency.