COMPRESSED AIR I
t is also one of the most energy-intensive and, amid the rising cost of electricity, operators are keen to find new ways to minimise consumption. Does reducing energy use simply require capital investment in the latest compressor
models that are optimised for energy performance? Graham Read, AMT & Digital Product
Management Director EMEIA Industrials Group at Ingersoll Rand urges manufacturers to look at the latest compressed air control options first as part of an ongoing maintenance strategy. He details the benefits of installing AI-driven, dynamic systems to help reduce energy use for existing installations.
THE BENEFITS OF MAINTENANCE Ongoing servicing and maintenance are essential to ensure equipment operates reliably and efficiently. A routine compressed air system service will keep machines operational for longer, helping avoid production downtime while also optimising the compressed air installation for energy efficiency. Over the years, the industry has evolved
from reactive emergency repairs, through scheduled servicing programmes, to predictive monitoring strategies. Today, continuous monitoring platforms
use machine learning to analyse real-time demand and automatically adjust compressor performance. Unlike traditional fixed- control strategies, these systems respond dynamically to fluctuations in production, ensuring compressed air supply closely matches actual plant demand. By moving beyond simple monitoring to
intelligent optimisation, businesses can achieve measurable improvements in energy efficiency, operational reliability and CO₂ reduction.
INTELLIGENT COMPRESSED AIR CONTROL AI-driven technologies are creating new opportunities for compressed air users to harness data to improve compressor performance and identify inefficiencies. These insights not only highlight any immediate issues that could lead to compressor failure but also allow operators to anticipate potential future problems by detecting signs of deteriorating machine performance. These digital platforms deliver tangible
business benefits through real-time monitoring, alarms and alerts that help reduce the risk of downtime. Cloud- based systems also enable remote sites to be monitored easily, while compressor performance can be optimised through machine parameter analysis and long-term trend monitoring. Through analysis of real-time data, sites
can build a much clearer picture of energy consumption and process inefficiencies and operational risk and take steps to adjust the compressed air system before problems arise.
COMPRESSED AIR ENERGY MANAGEMENT CALLS FOR DYNAMIC CONTROL
By Graham Read, AMT & Digital Product Management Director EMEIA Industrials Group, Ingersoll Rand
Compressed air, one of the workhorses of the modern factory, is an essential utility that keeps production lines running
MACHINE LEARNING Machine learning technologies, such as Ingersoll Rand’s Ecoplant, continuously monitor compressed air installations and automatically adjust system performance in response to changing production demands. The key advantage lies in the dynamic nature
of this control. Compressed air demand can vary significantly, and monitoring systems must adapt to these fluctuations in real time. This helps reduce energy costs and associated carbon emissions through improved efficiency, while also identifying maintenance issues before they become critical. For example, Ecoplant monitors compressor
performance dynamically and provides early warnings of potential failure risks. As a result, maintenance concerns can often be addressed before they lead to breakdowns, reducing unplanned downtime and supporting higher productivity. At the same time, Ecoplant stabilises
pressure levels and ensures that only the required amount of electricity is consumed, helping operators significantly reduce the energy used for compressed air generation.
CONTROL, ANYWHERE A major benefit of dynamic control is the ability to monitor and manage performance from virtually anywhere in the world. Specifiers should look for cloud-based remote access and comprehensive data logging capabilities that help maintain productivity
8 JUNE 2026 | FACTORY&HANDLINGSOLUTIONS
and support efficient maintenance planning. This remote visibility should be
complemented by clear on-site insights to support informed decision-making on the shop floor. Just as modern vehicles feature customisable settings that enhance the driving experience, dynamic control systems can provide intuitive dashboards that deliver real-time analytics, performance metrics and energy insights. Over the lifecycle of a compressed air
installation, equipment is often sourced from multiple manufacturers. To maximise the benefits of IoT connectivity, these machines should ideally generate data in a consistent format and adhere to common standards, regardless of supplier. In effect, all equipment should be speaking the same language. By standardising on open platforms,
operators can maintain complete visibility and control of their compressed air systems, irrespective of the equipment manufacturer.
Ingersoll Rand
www.compair.com/en
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