Episode 31: Turning Air Into Profit

Jason Reed

Alright, welcome back to The Big Dog Podcast! I’m Jason Reed, and as always, I’m here with Lisa Saunders. Today, we’re talking about something that, honestly, I think gets overlooked way too often—how you can actually turn your compressed air system into a profit center. Not just a cost you gotta swallow every month.

Lisa Saunders

Yeah, and I love this topic because, let’s be real, most folks just see compressed air as a necessary evil. But there’s so much opportunity if you know where to look. And, Jason, I know you’re a big fan of two-stage rotary screw compressors, so let’s start there. What’s the big deal with these?

Jason Reed

So, here’s the thing. A two-stage rotary screw compressor, like Kaishan’s KRSP2, splits the workload into two steps. Instead of one big push, you get a first stage and a second stage, each handling part of the compression. That means less mechanical stress, less heat, and—this is the kicker—up to 15 to 20 percent more airflow compared to a single-stage of the same horsepower. That’s not just a little bump. That’s a game changer for a lot of plants.

Lisa Saunders

And the payback period is actually pretty quick, right? I mean, we’re talking two to three years just on energy savings alone. I visited a plant last year—this was before they made the switch—and they were running a single-stage system that just couldn’t keep up. They were constantly fighting pressure drops, and the maintenance headaches were nonstop. Once they upgraded to a two-stage, it was like night and day. The reliability went up, and their energy bills went down. I think they were kicking themselves for not doing it sooner.

Jason Reed

Yeah, and it’s not just about the energy. You get durability, too. The KRSP2, for example, spreads the work out, so you’re not beating up your components. That means less wear and tear, and Kaishan actually backs it with a lifetime airend warranty. That’s pretty rare in this business.

Lisa Saunders

And let’s not forget Carlisle Construction Materials. They put in a KRSP2 with a variable speed drive and ended up getting an $11,000 rebate from their utility company. That’s real money back in your pocket, not just savings on the bill. It’s one of those stories that makes you realize, hey, this isn’t just theory—it’s happening out there.

Jason Reed

Exactly. And with VSDs, you’re getting even more efficiency at partial loads. So, you’re not just saving when you’re running full tilt. You’re saving all the time. That’s what makes these investments so smart. And, honestly, with two-stage units available as low as 30 horsepower now, it’s not just for the big guys anymore.

Lisa Saunders

Right, it’s opening up options for a lot more facilities. And, you know, if you’re still running a single-stage and wondering if it’s worth the switch, just look at the numbers. The payback is there, and the long-term reliability is hard to beat.

Jason Reed

So, let’s talk about system configuration. Because, honestly, even the best compressor can’t save you if your setup is all wrong. I’ve seen it too many times—folks relying on a single compressor for everything, and then when it goes down, the whole line stops. That’s a nightmare.

Lisa Saunders

Yeah, and that’s where multi-compressor setups come in. You’ve got your base load compressor handling the minimum demand, a trim compressor for those peaks, and a backup ready to go if something fails. It’s like having a safety net, but it also lets you sequence the workload so you’re not wearing out one machine faster than the others.

Jason Reed

Exactly. And, you know, I had a customer—this was a while back—who thought they could get away with just a VSD unit covering all the load swings. No backup, no trim. Well, guess what? Their main compressor tripped out during a critical run, and they were scrambling to get a rental in. It almost cost them a full day of production. That’s a lot of money down the drain for something that’s totally preventable with the right setup.

Lisa Saunders

And it’s not just about downtime. With a multi-compressor configuration, you can actually reduce your electricity usage. You’re only running what you need, when you need it. Plus, maintenance is way easier—you can take one offline without shutting down the whole system. It’s just smarter all around.

Jason Reed

And if you’re using a VSD-equipped unit, like the KRSP2, you can even skip the trim in some cases, but you still need some kind of backup. Even if it’s just a quick connection for a portable unit, you gotta have a plan. Otherwise, you’re just rolling the dice.

Lisa Saunders

Yeah, and I think a lot of people underestimate how much flexibility you get with the right configuration. It’s not just about avoiding disaster—it’s about running leaner, saving money, and making maintenance a whole lot less stressful. And, honestly, it’s one of those things we keep coming back to on this show: plan ahead, and your system will pay you back.

Lisa Saunders

Alright, so let’s get into remote monitoring, because this is where things get really interesting. Kaishan’s AirWatch system, for example, uses a wireless cellular modem, so you can check your compressor data in real time from your phone, your laptop, whatever. No more fighting with IT or dealing with factory network headaches.

Jason Reed

Yeah, and that’s huge. You can set alarms, track maintenance schedules, see your energy use, and even share access with your distributor or tech support. It’s almost like having a continuous audit running in the background. And, honestly, it’s saved a lot of folks from some nasty surprises.

Lisa Saunders

I’ve got a story about that, actually. There was a plant manager I talked to who got a late-night alarm on his phone—turns out, the compressor was pulling way more amps than usual. He caught it before it turned into a major failure. If he hadn’t had remote monitoring, he probably wouldn’t have known until the next morning, and by then, it could’ve been a disaster. Sometimes it’s the little things that make the biggest difference.

Jason Reed

And even if you don’t have remote access, Kaishan’s standard controller shows you critical info right on the screen—amps, volts, all that. So, if you see something out of whack, you can jump on it fast. No more guessing games.

Lisa Saunders

It’s all about having the right information at the right time. And, you know, as we’ve talked about in past episodes, the more you know about your system, the better decisions you can make—whether it’s maintenance, upgrades, or just day-to-day operation.

Jason Reed

Absolutely. So, if you’re looking to turn your compressed air system from a cost center into a profit center, start with the right equipment, set up your system smart, and keep your eyes on the data. That’s how you stay ahead of the game.

Lisa Saunders

Alright, that’s gonna do it for this episode of The Big Dog Podcast. We’ll be back soon with more ways to make your compressed air system work for you. Jason, always a pleasure.

Jason Reed

You too, Lisa. Thanks for listening, everybody. Catch you next time.