How Precision Manufacturing Cut Energy Costs by 50%

The Challenge

Precision Manufacturing, a leading aerospace component supplier, was struggling with rising energy bills. Their compressed air system relied on a fixed-speed 50 hp compressor that ran at full capacity around the clock—even when demand was low. On top of that, undetected air leaks were causing pressure drops and forcing the compressor to work harder than necessary.

The Solution

After a detailed audit, the company took three key steps:

1. Installed a Variable-Speed Compressor
   The audit revealed that air demand fluctuated between 22 and 45 cfm. By replacing the old fixed-speed unit with a 15 hp variable-speed rotary screw compressor, the system could now adjust output to match demand. This change alone cut energy consumption nearly in half.

2. Fixed Air Leaks
   Leak detection uncovered several major leaks that were wasting thousands of pounds in energy every year. Repairing these leaks stabilized system pressure and reduced unnecessary runtime.

3. Added Heat Recovery
   Instead of letting compressor heat escape, the company installed a recovery system that captured up to 90% of the waste heat. This heat was repurposed for preheating process water and warming the facility, reducing reliance on separate heating systems.

The Results

• Energy Savings: Power use dropped from 17.5 kW to about 9 kW—almost 50% less.
• Pressure Optimization: Lowering system pressure from 116 psig to 100 psig delivered an extra 8% savings.
• Leak Repairs: Eliminating leaks saved thousands annually.
• Heat Recovery: Reduced heating costs with a payback period of less than three years.

The Impact

By combining smart technology with simple maintenance, Precision Manufacturing achieved significant cost savings, improved reliability, and reduced its carbon footprint. This project shows how investing in efficiency pays off—both financially and environmentally.