The Hidden Power of Compressed Air in Food Manufacturing
Introduction
At Emergent Energy, we understand that compressed air is both a critical asset and a hidden cost in food manufacturing. From sealing in the freshness of coffee beans and packaged goods to powering pneumatic equipment, compressed air is indispensable. Yet inefficiencies—such as leaks, improper compressor management, and unnecessary operation during downtime—can drive up energy costs, compromise product quality, and hinder sustainability efforts.
The solution lies in real-time energy monitoring and optimization. By leveraging advanced cloud-based technology, we help manufacturers uncover and address these hidden inefficiencies, delivering measurable energy savings and operational improvements.
The Role of Compressed Air in Food Manufacturing
Compressed air is as essential as water, gas, and electricity in food production. It’s used for:
- Nitrogen generation
- Vacuum and dust collection filtration management
- Operating pneumatic equipment
However, food manufacturers face significant challenges:
- Strict Food Safety Regulations - Air must remain clean, dry, and contaminant-free to comply with FDA and ISO 8573-1 standards.
- High Energy Dependency - Compressed air can account for 30–50% of a facility’s total electrical energy usage.
- Inefficiencies That Drain Resources - Issues like undetected leaks, pressure fluctuations, and inefficient compressor sequencing can lead to substantial energy waste and increased operating costs.
Common Inefficiencies and Our Approach
1. Leaks – The Silent Spoiler of Efficiency
Up to 50% of compressed air can be lost through small, undetected leaks. Even minor leaks force compressors to work harder, while reducing productive air usage, which not only increases energy costs but reduces available system capacity as a growing portion of the system is being consumed by leak load rather than process load.
2. Short Cycling and Inefficient Compressor Management
Improper sequencing of compressors often leads to short cycling. This is especially prevalent on systems that operate with 3 or more compressors with insufficient air storage. A high capacity (multi-air compressor) system without sufficient storage will likely face rapid system cycling as spikes in air demand will cause system pressure drops. Since the air compressors are typically staged based on system pressure, a sudden pressure drop will cause frequent starts and stops.
3. Air Misuse and Downtime Waste
Many facilities continue running their compressed air systems 24/7—even during non-production hours—leading to unnecessary energy consumption. Capacity management during down days will help to ensure the correct compressor mix is used during the peak demand and low demand hours of operation.
Inside the Panoramic Power Dashboard for Compressed Air
Real-time monitoring is the key to transforming compressed air inefficiencies into measurable savings. With Panoramic Power’s cloud-based dashboard, manufacturers gain complete visibility into their system’s performance. Key metrics include:
Figure 1 – Leak load management during off hours of operations. Identifying leak load air demand.
Monitoring compressor start/stop cycles can identify and reduce short cycling, leading to improved energy efficiency, reduced system run hours and improve system longevity.
Figure 2 – System Short Cycling of (Orange). Leverage compressed air storage and proper pressure band settings to reduce system starts / stops.
These various metrics (KW Input, system pressure and dew point, air flow at main headers and point of use) integrate into actionable insights, allowing sustainability managers and plant operators to optimize performance, reduce waste, and document savings—all in real-time.
Case Study: How Lavazza Reduced Compressed Air Costs
At Lavazza’s West Chester, Pennsylvania facility, compressed air accounted for 37% of total energy usage. Recognizing the urgency to reduce this cost, Lavazza partnered with Emergent Energy and leveraged Panoramic Power’s real-time monitoring technology—backed by PECO’s incentive program—to address these challenges.
The Solution
Together, Emergent Energy implemented several key measures at LaVazza.
- Leak Detection and Repair - Rapid identification and repair of leaks to plug major energy drains.
- Identified pressure drops within the distribution system - Minimizing pressure drops and implemented a production area ring main to high air consumption equipment.
- Eco-mode Settings - Configuring compressors and nitrogen generators to shut off during low-demand periods, thus reducing unnecessary purge cycles and frequent system cycling; reducing energy consumption.
The Results
- Annual Energy Savings: Approximately 2.5 million kWh
- Cost Savings: An estimated $150,905 per year
- Project Cost: $200,000 – fully offset by $250,000 in PECO incentives
- ROI: The project effectively paid for itself through the incentive program
Reflecting on the project, Kevin Wong, General Manager of Emergent Energy explained:
“There are so many run-hours on a compressed air system like this, that even very minor changes can have huge impacts on energy use.”
Lavazza’s Manufacturing Engineer, Josh Miller, added:
“It was a huge opportunity for Lavazza to be more responsible with our energy use, and also just reduce our monthly spend on electricity.”
This case study clearly demonstrates how targeted system upgrades, informed by real-time monitoring, can transform compressed air from a hidden expense into a strategic asset.
The Future of Compressed Air Optimization
As real-time energy and carbon monitoring become increasingly integral to operations, manufacturers who invest in these technologies will gain a competitive edge. Not only will they lower operating costs, but they will also enhance sustainability and more effectively meet stringent food safety requirements.
Conclusion: A Smart Investment for the Future
Investing in real-time compressed air monitoring isn’t just about cutting costs—it’s about building a more efficient, sustainable, and reliable production environment. With smart analytics from Panoramic Power powering our solutions, we help manufacturers turn compressed air from an invisible expense into a measurable competitive advantage.
Real-time monitoring helps manufacturers cut energy costs, delivering significant annual savings.
Contact Emergent Energy today to learn how Panoramic Power’s Energy Intelligence Solutions can deliver measurable savings for your facility.
About the Author
Kevin Kai Wong is the General Manager at Emergent Energy Solutions and a Panoramic Power partner who serves clients in the USA. With over 20 years of experience delivering integrated energy solutions, Kevin combines technical expertise with a practical, results-driven approach to help organizations achieve emissions reductions and operational efficiency.