Compressed air used in industrial processes is recognised as one of the most energy-intensive systems in a plant, consuming up to 90% of total energy. The use of more energy-efficient solutions in manufacturing is thus seen as key to reducing operational costs while also helping to meet economic and environmental sustainability targets.

“Efficiency starts with smart equipment and advanced integrated technologies,” says Atlas Copco Compressor Technique sales manager: customer services and optimisation Saien Rugdeo. “Customers can cut energy consumption by up to 60% by upgrading to energy-efficient solutions like variable speed drive compressors for example. Further savings can be unlocked by optimising system pressure and eliminating air leaks, ensuring energy is used efficiently and not wasted.”

Rugdeo explains that most of the electrical energy consumed by a compressor is converted into thermal energy and that the use of waste energy recovery technology enables manufacturers to reclaim much of the energy consumed during compression.

Atlas Copco notes that its Energy Recovery solution uses an integrated heat exchanger to capture most of the wasted heat for reuse, either as hot air through ducting connected to the compressor or as hot water using a water supply connected to the compressor.

Rugdeo says that, depending on the configuration, the system can recover up to 94% of the heat generated during compression, either as hot air or hot water. The recovered energy can be repurposed across a range of applications, including laundries, space heating, hot water or steam generation, industrial processes such as automotive and chemical refining, pharmaceutical drying and sterilisation, food and beverage pasteurisation and cleaning, textile dyeing, and electronics clean room sterilisation.

Rugdeo stresses the importance of understanding compressor types to select the right solution, noting: “Air-cooled compressors offer a straightforward, cost-effective retrofit, even for smaller units. In contrast, water-cooled compressors often require added infrastructure like pumps, heat exchangers and control valves, making Energy Recovery economically viable primarily for units above 22 kW.”

Rugdeo further notes that the savings potential of an Energy Recovery system depends on several factors including compressor type and size, operating hours, cooling method, and the design of the compressed air system.