MONITORING & METERING
HOW AI MONITORING & CONTROL IS TRANSFORMING COMPRESSED AIR INSTALLATION EFFICIENCY
Ecoplant, monitor compressed air installations and adjust to respond to production changes. The important consideration is the dynamic
nature of this control. Compressed air demand can fluctuate, and any monitoring system needs to adapt to these changes in real-time. This will help to reduce energy costs and the associated carbon emissions through optimised efficiency, as well as to identify any maintenance concerns that need addressing. Ecoplant, for example, monitors compressor performance dynamically, providing timely alerts on potential failure risks. As a result, maintenance issues are identified quickly and can often be resolved before they occur, reducing unplanned downtime for improved productivity. At the same time, Ecoplant ensures pressure
Compressed air is one of the most energy-intensive utilities in manufacturing, yet it is also one of the least optimised. Amid rising electricity costs, manufacturers are turning to AI-driven monitoring and control systems to unlock significant efficiency gains across their compressed air installations. Graham Read, AMT & Digital product management director EMEIA Industrials
Group at Ingersoll Rand, explores how dynamic, data-led control, is having a positive impact on compressed air management
T
he annual maintenance costs of a compressed air system can amount to
10% or more of the total cost of investment, a percentage that varies depending on the size and the type of system and compressors. The energy cost of a compressed air system accounts for between 70% and 80% of the total cost of investment, and energy that is lost due to inefficiencies of a non-optimised system can be as high as 30%. It stands to reason, therefore, that on-going
servicing and maintenance is essential to make sure equipment runs reliably and efficiently, and can optimise energy use. As a result, over the years the industry has moved from reactive- based emergency repair, through scheduled servicing to predictive monitoring. Now, continuous monitoring platforms use
machine learning to analyse real-time demand and adjust compressor performance automatically. Unlike traditional fixed-control strategies, these systems respond dynamically to fluctuations in production, ensuring that compressed air supply matches actual plant demand. In this way, by moving from simple monitoring to optimisation, customers can realise
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measurable improvements in energy efficiency, operational reliability, and CO2 reduction.
INTELLIGENT COMPRESSED AIR CONTROL AI technologies are now creating a real opportunity for compressed air users to consider how data can help improve compressor performance and highlight any inefficiencies. These insights not only show any immediate issues but also enable operators to forecast for any potential future problems, based on deteriorating machine performance. Furthermore, predictive maintenance models based on real-time data can be established to help reduce energy consumption, improve process efficiencies and limit any risks. Digital platforms can provide tangible benefits to a business’ bottom line, with real-time monitoring, alarms and warnings to reduce the risk of downtime. Cloud-based systems mean remote sites can be monitored easily, and compressor performance can be optimised with machine parameters and trend analysis over time.
MACHINE LEARNING Machine learning systems, such as Ingersoll Rand’s
ENERGY & SUSTAINABILITY SOLUTIONS - Summer 2026
levels are stabilised intelligently and that only the necessary amount of electricity is used, helping operators reduce their energy consumption from compressed air generation considerably.
CONTROL, ANYWHERE A key benefit of dynamic control is that performance can be monitored and managed from anywhere in the world. Specifiers should expect cloud-based remote access and unlimited data logging to help keep productivity high and maintenance efficient. And, this remote analysis should be matched
with on-site visibility to help facilitate smart decision-making on the shop floor. Just as modern vehicles are equipped with customisable settings to enhance the driving experience, dynamic control can enable operator-friendly and intelligent dashboards to provide real-time analytics and energy insights. Over the years and through various compressed
air product lifecycles, equipment may have been purchased from many different brands. To connect with IoT technology easily and efficiently, these machines should ideally be producing data that comes in the same format and complies with the same standards, regardless of which company supplied them. Essentially, they should all be speaking the same language. However, as things stand, too many systems are running on proprietary protocols and standards. This locks up their data in a way that makes it awkward and inconvenient to process, limiting the ways in which machines can interact with IoT technologies. Operators should standardise on open
platforms to help stay in control of their compressed air installation at all times, no matter who the manufacturer is.
Ingersoll Rand
www.ingersollrand.com/en-gb/
www.essmag.co.uk
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