One of the most striking findings of this fascinating research into compressor usage in the UK today is that unexpected breakdowns are more common than you might think and can have a significant impact on production.
An incredible 41% of respondents admitted to having experienced a compressor breakdown in the past year. In more than 20% of cases, the compressor was out of action for more than a week and the same number said it took between two days and a full week for the compressor to come back into operation.
Implement a proactive maintenance programme
As a result of these breakdowns, 54% suffered downtime, which in one case cost up to £20,000 in lost production.
The importance of implementing a proactive maintenance programme could not be clearer. What's encouraging is that most manufacturers seem to agree. When selecting a new compressor, 54% said that the strength of the servicing and maintenance package offered alongside the machine was one of the most influential factors in the decision-making process. An equal number cited purchase price as a major influence.
In fact, the only factor rated more highly than these two considerations was the energy efficiency of the compressor.
It would have been interesting if a similar survey had been carried out 10 years ago, so that we could compare the findings. In the absence of such a comparison, it's fair to suppose that energy efficiency probably wasn't such a major consideration in 2005. However, the landscape has changed dramatically since then.
The combination of tough trading conditions, rising energy prices, growing awareness of sustainability and regulatory pressures has placed energy efficiency firmly under the spotlight as both a financial and reputational priority.
Achieving energy efficiency begins with selecting the right type of compressor for a particular application and here it is important to engage with a highly experienced, trained and accredited sales engineer from a reputable manufacturer with a wide range of energy-efficient compressor types and sizes to select from.
However, the working life that is expected from a compressor should also be borne in mind. Most survey respondents (41%) said their compressors were between six and 10 years old, while 12% said the average age of their compressors was between 11 and 20 years old.
Maintaining energy efficiency over that period requires that the compressors receive regular professional attention. This will ultimately help to keep running costs under control.
At Atlas Copco Compressors, we work with our customers to achieve this in a number of ways.
Firstly, we offer a variety of energy performance measurement tools, from a simple Energy Performance Calculator (EPC) assessment to a more comprehensive AirScan audit, utilising the latest technology to accurately assess the performance of the entire compressed air network and making recommendations to enhance efficiency and output.
By pinpointing and rectifying common causes of reduced performance – from leakages to poor alignment of air supply and demand – energy bills can be cut by thousands of pounds.
In one recent project undertaken by Atlas Copco, a leakage detection programme instigated across a UK vehicle manufacturing plant identified leaks costing £102,000 a year in lost energy.
It pays to use genuine spares
Other factors that can help reduce total lifecycle costs include the use of genuine spare parts from the manufacturer, which are typically more robust and better suited to the original system. A growing number of manufacturers are also deploying our remote monitoring service, SMARTlink, which provides continuous real-time data and downloadable reports on key performance criteria.
Adopting such strategies can have a significant impact on the performance of compressors, not only reducing running costs but also limiting the incidence of unexpected breakdowns and the costs associated with them in terms of lost production.
This survey provides a fascinating insight into compressor usage in the UK today and we'd urge manufacturers to consider the results in light of Atlas Copco's guiding principle: there is always a better way.
