Why Compressed Air Should Not Be an Afterthought

Compressed air is an indispensable energy source for many companies, essential to numerous business processes — but costly and unsafe when applied incorrectly.

During (new) construction, the compressed air distribution network often receives attention only at the very last stage — and not always with sufficient technical expertise. This frequently comes at the expense of efficiency and safety. A properly calculated and dimensioned distribution system will save the user significant energy costs by minimising pressure losses while improving ease of use and safety.

Save Costs with an Efficient and Safe Compressed Air System

Compressed air is expensive because more than 85% of the electrical energy consumed is converted into heat, and only 15% into compressed air energy. This is why it is essential to integrate the compressed air network into the design at an early stage, to avoid energy losses caused by pressure drops and to consider the safety of the users.

Focusing on leaks to save compressed air costs is correct, but pressure losses are often a hidden cost factor. For every additional bar of pressure your compressor must generate to compensate for losses, energy consumption rises by 7%. Correct dimensioning prevents these unnecessary costs.

Example calculation:

To produce 50 m³/h of compressed air at 7 bar, your compressor requires approx. 6 kWh. To transport this 50 m³/h through 100 metres of Ø50 mm steel piping requires an additional 1.5 kWh (a 25% energy increase). Using Ø75 mm piping, this costs only 0.21 kWh (3.5% energy increase). Over 15 years, the “savings” of using smaller piping diameters will cost you over €6,000 per 100 metres of piping in additional energy costs.

Due to a lack of technical knowledge among decision-makers and many installers, as well as the absence of proper specifications and calculations, costs are often “saved” by using cheaper and/or smaller materials in compressed air distribution systems — at the expense of significantly higher energy consumption for the end user. The consultants at Q Plus B.V. are happy to advise you further.

Make Safe and Informed Choices

In addition to choosing the correct system dimensions, the use of safe components also helps reduce costs by preventing damage to tools, surroundings, and users.

Protect Your Tools from Excessive Wear with CartReg and ToolReg

Compressed air tools are usually designed to operate at a maximum of 6.3 bar. By using pre-set pressure regulators such as CartReg or ToolReg, you protect your tools against excessive wear and avoid wasting expensive compressed air. Such an investment quickly pays for itself.

Store Hoses Safely with a Braked Hose Reel

Moving back from the tool towards the compressor, we soon come to the connected hose. It is essential that hoses can be stored properly when not in use. This prevents unsafe situations such as tripping hazards, slipping accidents, or hoses being run over and damaged.

A hose reel is the ideal solution — and always choose a braked hose reel. The spring forces in hose reels are often underestimated; if an unbraked reel is released uncontrolled, dangerous situations arise due to whipping hoses and likely damage to the reel itself. Q Plus B.V. recommends the braked hose reels from Zeca.

Venting Quick Couplings Ensure Safe Disconnection

For connecting and disconnecting tools, use a venting quick coupling. These couplings ensure that the line is depressurised first, before safely disconnecting. This prevents tools or hoses from shooting away and causing damage or injury.

Prevent Unsafe Situations in Case of Hose Breakage with HoseGuard

If a hose does get damaged or run over, it is reassuring to know it will be shut off immediately. The ingenious, patented design of the HoseGuard detects a broken hose or line and instantly closes off the airflow. This prevents unsafe situations with whipping hoses and avoids excessive energy losses.