Episode 16: Optimizing Compressed Air Systems

Jason Reed

Welcome back to the Big Dog podcast! Wherever you are, whether in your plant, your home, or somewhere in between, we're thrilled to be with you today.

Jason Reed

Alright, Lisa, let's kick this one off. As you know, you've got three main kinds of compressors—centrifugal, reciprocating, and rotary screw. Now, rotary screws, they're like the MVPs of the compressed air world. Long life, low cost of ownership, and they just keep getting more efficient.

Lisa Saunders

Right. And they’re everywhere, too. Most industrial and commercial facilities seem to lean toward rotary screw compressors. But why do you think they’ve edged out the other types?

Jason Reed

Efficiency. Pure and simple. They deliver stable airflow, low maintenance, and they’re just designed to handle a range of loads without breaking a sweat. Compare that to centrifs—they’re more for high-volume, continuous flow—and reciprocating compressors, which are great for smaller jobs, but can struggle in larger environments.

Lisa Saunders

So, rotary screws kinda hit that sweet spot, huh?

Jason Reed

Exactly. But here’s the kicker—getting the type right is just the start. Sizing? That’s where a lot of folks mess up.

Lisa Saunders

Oh, yeah. I actually saw that firsthand when I visited this one plant. They’d oversized their compressor because they were worried about “future expansion,” and it was—

Jason Reed

Let me guess—cycling constantly?

Lisa Saunders

Exactly. Constantly starting and stopping, which created all these headaches. It overheated, there was oil carryover, and maintenance costs just kept climbing. They eventually had more downtime than they could afford.

Jason Reed

Classic mistake. Oversized compressors are like... well, like putting a linebacker as a quarterback. Sure, they can do the job, but it’s not efficient, and they’re gonna burn out fast.

Lisa Saunders

That’s a good analogy. And on the other end of the spectrum, if you undersize, you’re risking not meeting demand altogether, right?

Jason Reed

Right. And then you’re running the poor thing into the ground, which shortens its lifespan real fast. But the real problem with oversizing? It locks in inefficiency from day one—bigger energy bills, more wear and tear. It’s a mess.

Lisa Saunders

That’s why sizing is so critical. It’s not about going big or playing it safe—it’s about getting it just right for your actual needs. Data, analysis—it all comes into play.

Jason Reed

Exactly. And it saves a ton in the long run. Trust me, nobody wants to be stuck solving problems later because they didn’t plan properly upfront.

Lisa Saunders

So true. And there's more to this, right? Like, how you configure the compressors in a system. I know some strategies involve splitting the workload across multiple units...

Lisa Saunders

Right, so we’ve covered why sizing is critical. Now, let’s talk about compressor configurations—this idea of splitting the workload across multiple units. How does that help, exactly?

Jason Reed

It’s all about flexibility. A multi-unit setup uses a base compressor for constant demand, a trim compressor for handling spikes, and a backup for emergencies. This way, instead of a single unit trying to do it all, you’ve got a team working together. It’s smarter and way more efficient.

Lisa Saunders

Right, so no single compressor is overworked. But how does this actually cut costs?

Jason Reed

Simple—by matching output to demand. Let’s say your base compressor handles your usual daily needs. If demand suddenly spikes, the trim compressor kicks in. But when demand dips? The trim unit backs off, and you’re not wasting energy. Plus, with a backup on standby, you’re covered if, you know, something goes wrong.

Lisa Saunders

That’s clever. It’s like having a bench in sports—always ready to fill in when needed.

Jason Reed

Exactly! And downtime is minimized, which is huge. I mean, downtime isn’t just inconvenient—it costs real money. Having that backup eliminates a ton of headaches.

Lisa Saunders

But this only works if the compressors are, well, in good shape, right?

Jason Reed

Oh, definitely. Maintenance is crucial. Without it, even the best setup can fail. Did you know the average compressed air system loses 30-50% of its air to leaks?

Lisa Saunders

Wait, 50%? That’s massive!

Jason Reed

Yeah. And here’s the kicker—a lot of those leaks are silent. You can’t just listen for hissing and call it good. You need ultrasonic detection or a solid maintenance plan to catch them. Leaving them unchecked is literally throwing money away.

Lisa Saunders

And it’s not just leaks, right? Things like overheating or oil carryover can spiral out of control without regular checkups.

Jason Reed

Absolutely. Overheating ruins internal parts, oil in the air system can contaminate tools... it snowballs. A proactive maintenance plan cuts costs by up to 70% compared to reactive fixes.

Lisa Saunders

So, maintain the system, prevent leaks, and strategically shut down compressors when they’re not needed. This is starting to sound like a pretty disciplined operation.

Jason Reed

It is. Discipline is everything. I’ve seen cases where just tightening operations—turning off compressors running at partial loads—saved tens of thousands in a year.

Lisa Saunders

Wow. It really is like coaching a team: the right lineup, a solid game plan, and making adjustments as needed.

Jason Reed

Exactly. And it’s not just about saving energy—it’s about keeping the whole operation smooth.

Lisa Saunders

We’ve talked about the importance of discipline in compressor management—maintaining systems, preventing leaks, and optimizing operations. Now let’s look at how advanced control technologies, like VSDs and master controllers, take that discipline to the next level. Jason, what makes them such game-changers?

Jason Reed

It’s all about precision, Lisa. VSDs, for example, adjust the speed of the compressor to match demand. So instead of running at full tilt all the time, you're using just enough energy for what’s needed. It’s smarter, saves power, and reduces wear and tear. But they’re not perfect for every setup.

Lisa Saunders

Right, I’ve heard that. They work best in that middle range—neither too high nor too low, because extremes kinda cancel out the benefits, right?

Jason Reed

Spot on. And then you’ve got master controllers. Get this—they can network every compressor in your system, even if they’re different brands, and run them in a tight pressure band—like, within +/-2 PSIG. The efficiency gains are huge.

Lisa Saunders

That’s incredible. And it seems like that’s where expert audits really come into play. I mean, identifying those inefficiencies—it’s not something you can eyeball, right?

Jason Reed

Exactly. You need fresh eyes. These audits go deep, analyzing your system—demand patterns, peak times, everything—and they uncover issues you’d never spot yourself. Like leaks that you literally can’t hear. The savings from fixing those alone can be mind-blowing.

Lisa Saunders

I bet. Having an expert partner sounds like having, well, a skilled coach. They don’t just point out what’s wrong—they help you optimize your whole game plan.

Jason Reed

Yeah, it’s a total game-changer. They bring in tech, strategies, and, honestly, peace of mind. With the right partner, you’re not just fixing issues—you’re preventing them. Think of it as making sure your star players stay on the field and in peak condition.

Lisa Saunders

I love that analogy. So, Jason, if we’re summing it all up, what’s the bottom line for listeners?

Jason Reed

It’s simple—advanced tech like VSDs and master controllers can transform efficiency. Combine that with expert audits to identify issues, and you’ll save energy, extend equipment life, and reduce downtime. Play smart, and you’ll win big.

Lisa Saunders

Perfectly put. And, really, it’s about being proactive—choosing the right equipment, staying on top of maintenance, and bringing in partners who know the playbook. It all adds up to smoother operations and lower costs.

Jason Reed

Couldn’t have said it better myself, Lisa. And that’s all for today, folks. Great talking about this with you.

Lisa Saunders

Same here, Jason. Thanks for listening, everyone. On that note, we’ll catch you next time!