Dynamic compressor control system with energy savings
Fourth Quarter 2025
Pneumatic systems & components
CompAir has launched Ecoplant, a dynamic, compressed air management solution that adjusts compressor parameters in real time, offering up to 30% reductions in energy costs and CO2 emissions.
Generating compressed air can be very energy intensive and many conventional control systems are not designed to adapt to fluctuations in air demand in real time. As a result, up to 50% of compressed air can be wasted through inappropriate use and artificial demand, combined with failure to detect pressure drops or leaks.
Ecoplant is different. Using dynamic, AI-based control rather than static control, the system monitors key metrics throughout the network. It then adjusts compressor setpoints accordingly and selects the optimal operating configuration.
Ecoplant also allows easy identification of air leaks, which can then be isolated. Health insights can predict and warn of potential issues before they occur, helping to prevent costly downtime.
Remote, cloud-based monitoring
The cloud-based management solution combines intuitive predictive maintenance, generated by the algorithm and SaaS proactive analytics and controls. This enables operators to monitor issues from anywhere in the world.
Immediate maintenance alerts and one-click monitoring allow teams to respond quickly, helping to avoid costly downtime while realising cost savings through improved production efficiency.
Customised dashboard and reporting
By monitoring the compressed air system dynamically, operators can make better decisions based on improved data. In addition, Ecoplant is customisable to each site’s compressed air system needs, including monitoring energy consumption and operation.
Unlimited historical data is also readily available. Trends, such as periods of inactivity or lower demand, can be tracked for the entire system or for individual processes or compressors. Simple comparisons between different periods can also be performed in a matter of seconds, all helping to monitor inefficiencies over time and take remedial action.
Andrea Milia, business development manager from CompAir said, “Over 70% of manufacturing facilities use compressed air systems, which typically represent between 10 to 30% of the site’s average annual electricity costs. Combined with equipment efficiencies, costly maintenance and poor air quality, generating compressed air can be costly. “With its dynamic control managed by machine learning, Ecoplant offers a new approach for operators to monitor and manage their compressed air system remotely, helping save maintenance costs and avoid equipment downtime.”
An annual value calculator is available on the company’s website to help operators calculate predicted compressed air system savings by installing Ecoplant in their facility.
For more information contact Kelly Jones, CompAir South Africa, +27 11 345 2200, [email protected], www.compair.com/en
Further reading:
How to clean compressed air effectively
Pneumatic systems & components
ISO-Reliability Partners has taken another step in bringing to market highly effective solutions to combat contamination in all its forms. The locally designed and patented Air Wizard inline water trap is proudly manufactured in South Africa. It has been SABS tested for the separation of water, oily fluids, rust and solid particulates from pneumatic compressed air or gas lines.
Read more...
Compressed air piping design
Artic Driers International
Editor's Choice Pneumatic systems & components
When designing a compressed air pipeline, remember that size matters. The internal size of the pipe, along with the pressure and air volume, determine the velocity of the compressed air in the pipeline.
Read more...
Top questions about pressure gauges
SA Gauge
Editor's Choice Pneumatic systems & components
Some questions never go out of date, and in our industry, a few have been asked for decades. At SA Gauge, we hear them every week. Here are the ten questions we hear most often, and the practical answers that can save time, money and frustration.
Read more...
Achieving clean and dry compressed air for faultless operation
Artic Driers International
Pneumatic systems & components
Compressed air is an expensive source of motive power so it makes good sense to supply clean, dry compressed air to your distribution system.
Read more...
Controlling pneumatics via IO-Link
ifm - South Africa
Pneumatic systems & components
Pneumatic airboxes control cylinders or actuators using compressed air, and are found in a wide range of industrial applications.
Read more...
The role of analogue gauges in a digital world
SA Gauge
Pneumatic systems & components
With so much focus on digital systems, remote monitoring and automation, it’s easy to assume that traditional analogue gauges are outdated. Yet in almost any plant, mine or processing facility, you’ll still find them in daily use. There’s a good reason for this.
Read more...
It’s full steam ahead for SKF’s sustainable leak detection solution
SKF South Africa
Pneumatic systems & components
One of SKF’s key customers based in Cape Town, which depends on steam systems for its production processes, was facing costly challenges related to high energy consumption and excessive maintenance hours. SKF recommended the TKSU 10 ultrasonic leak detector as a more streamlined, user-friendly alternative.
Read more...
Is your compressed air system sustainable?
Artic Driers International
Pneumatic systems & components
We are all aware that compressed air is an expensive source of motive power, but do we actually know what the cost is?
Read more...
Reliable, flexible and cost-effective rental compressed air
Pneumatic systems & components
More businesses are turning to Integrated Air Solutions for rented on-demand compressed air, without the burden of capital expenditure.
Read more...
It’s full steam ahead for SKF’s sustainable leak detection solution
SKF South Africa
Pneumatic systems & components
One of SKF’s key customers based in Cape Town, which depends on steam systems for its production processes, was facing costly challenges related to high energy consumption and excessive maintenance hours. SKF recommended the TKSU 10 ultrasonic leak detector as a more streamlined, user-friendly alternative.
Read more...
printer friendly version