Compressed Air Systems

Compressed air is the most expensive utility in your plant. Detect leaks, optimize compressor staging, and cut energy waste by 20-30%.

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20-30%

Energy Reduction

Typical savings from leak repair + staging optimization

$0.25

Cost per kWh of Compressed Air

Industry average most plants are unaware of

30%

Of Energy Wasted on Leaks

Average compressed air system loses 30% to leaks

Find Every Dollar of Waste

Physics-based models calculate true cost of compressed air per CFM, per zone, per shift.

Leak Detection & Correlation

Correlate pressure decay curves with ultrasonic leak survey data. A 1/8" leak at 100 PSI wastes $1,200/year. TwinEdge finds them automatically.

Specific Power Tracking

Monitor kW per 100 CFM in real time. Industry benchmark is 18-22 kW/100 CFM. Most plants run at 25-30 kW/100 CFM without knowing it.

Staging Optimization

Analyze compressor sequencing to eliminate simultaneous blow-off. Load/unload patterns reveal $10K-50K/year in wasted modulation energy.

Thermal Monitoring

Discharge temperature trending detects fouled coolers and failing valves weeks before a trip. Intercooler approach temperature tracks heat exchanger health.

System Coverage

Rotary Screw CompressorsDischarge pressure/temp, oil temp, motor current, vibration, air flow

Refrigerated DryersDew point, refrigerant pressure, condensate drain cycles

Air ReceiversPressure, fill/drain rate, safety valve status

Distribution PipingZone pressure, differential pressure across filters, flow metering

Your Most Expensive Utility, Under Control

Most plants save $25,000-$100,000/year on compressed air within the first 90 days of monitoring.

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