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Your compressor is too small. So you buy a bigger one. And your energy bill goes up. That is what most people expect.
Flying Spares proved it does not have to work that way. The business moved to a larger site and needed more compressed air. They fit a bigger compressor and still used less power. These are real air compressor energy savings, measured over a full year.
Here is exactly what they did, and the numbers to back it up.
The problem: a small compressor in a bigger building
Flying Spares relocated to a larger facility. The business was growing, and the new site needed more compressed air than before.
Their old compressor could not keep up. It was an 11kW fixed-speed machine. Fixed speed means it runs flat out whenever it is on, even when demand is low. That wastes power.
So they had a choice. Push an undersized compressor harder, or fit the right machine for the new site.
What Air-Mech did
Air-Mech surveyed the site first. We looked at how much air the new operation actually needed, instead of guessing.
Then we fit an 18.5kW variable speed drive screw compressor with an integrated dryer.
A variable speed compressor changes its motor speed to match demand. When the site needs less air, the motor slows down and draws less power. When demand rises, it speeds back up. It only uses the energy the work needs.
Why a bigger compressor used less power
This is the part that surprises people. The new compressor is bigger on paper, 18.5kW against 11kW. So how did it cut energy use?
There are two reasons.
First, variable speed. The old fixed-speed unit ran flat out all the time. The new one matches demand and idles down when air use drops.
Second, the right size for the job. An undersized compressor working flat out is inefficient. A correctly sized variable speed machine, with a modern dryer, does the same work for less.
The result is a compressor that handles more demand and still saves energy.
The air compressor energy savings, in numbers
Air-Mech measured the new system over a full year. Here is what Flying Spares gained:
- 4,322 kWh saved every year.
- £1,729 cut from the annual energy bill.
- 22,847 kWh total annual consumption on the new system.
- 14% saving on maintenance costs over five years.
A bigger compressor, more capacity for a growing site, and a smaller bill. Every figure here comes from the live Air-Mech case study, not a sales sheet.
Andy Thwaites, TSD Manager at Flying Spares, said:
The expertise and tailored solutions from Airmech were crucial during our site expansion. Their advanced compressed air system not only enhances our operational efficiency but also offers significant energy savings.
See how we could do the same for you
Your site is not Flying Spares. Your air demand, your hours, and your old kit are all different. So the savings start with a look at your real setup.
Air-Mech surveys your site, measures your actual air demand, and shows you where the waste is. If a variable speed upgrade pays back, we tell you. If it does not, we tell you that too.
Want the same air compressor energy savings? See how we could do the same for you. Book a survey.