6 Cost Saving Statistics In Support Of Preventative Maintenance

Preventative maintenance for your air compressor is one of the best investments you can make to keep your equipment running smoothly and your bottom line strong.

It’s often treated as an afterthought, or something to consider when a breakdown occurs, but following a regular checklist can help. But the data tells a different story. Regular, preventative maintenance extends equipment life, reduces costly downtime, and improves energy efficiency. While budgeting for it may be challenging at times, the cost of repairs is often higher. Here are six powerful statistics about preventative maintenance that show why it’s needed for performance and profitability.

Energy Conversion Efficiency

Between 80-90% of the electrical energy used by an air compressor is converted to heat. A properly designed heat recovery unit can recover 50-90% of this available heat. This heat can be used for practical uses such as heating water, warming indoor spaces, or supporting any industrial process. Converting this heat can lead to substantial cost savings.

Lifetime Energy Costs

The lifetime energy costs of running an air compressor can be 20 times the initial purchase price. This makes regular maintenance of your air compressor essential for cost savings over time. You can follow a routine maintenance schedule and checklist to ensure to keep your energy costs down in the long-term. When components wear down over time, the unit needs to work harder. This routine maintenance can help keep consistent output by replacing worn parts for optimal airflow and pressure levels, while preventing leaks.

Air Leak Cost Impact

Plants that have not been well maintained can waste 20 percent of their total compressed air production capacity through leaks. A single 1/4-inch leak in a compressed air line can cost a facility between $2,500 and $8,000 annually, demonstrating the significant financial impact of neglected maintenance. Addressing air leaks as soon as they are detected can help you maintain energy efficiency.

Maintenance Cost Percentage

The good news is that maintenance cost is a relatively low percentage of the total cost of ownership, making up about 8 to 12 percent of the total. Annual maintenance costs are usually between 5-10 percent of the cost of the compressor. This routine maintenance is crucial for the reliability, efficiency, and longevity of the compressor. Without this regular upkeep, small issues like air leaks, clogged filters, or inadequate lubrication can escalate into larger problems that cause downtime, require repairs, and increase the cost of ownership.

Filter Cleaning Energy Savings

Cleaning filters and reducing supply resistance to the air compressor to below 200mmAq can reduce energy consumption by 1 percent. This energy reduction becomes an effective way to lower operating costs and improve efficiency of your compressed air system. This efficiency can lead to strong cost savings over time. Filters can be cleaned and replaced as part of the regular maintenance routine.

Inherent System Inefficiency

The reality is that air compressors are naturally inefficient, due to 80 percent of the energy output being converted to heat. Routine maintenance can help you maximize the efficiency of your system so that you are able to make the most of it.

Hire A Compressor Maintenance Company You Can Trust

An experienced and trusted compressor maintenance company will help you get the most out of your organization’s air compressor. Compressor Services has experienced technicians serving Northern Illinois and Southern Wisconsin.

Contact us today to set up a preventative maintenance plan for your facility.