Table of Contents
Your old compressor still runs. That is the problem. Because it runs, it never makes the case for its own replacement. It just quietly costs you more every year, in energy, in repairs, and in the risk of a failure you did not plan for. This post is a spotlight on one Air-Mech service: compressor upgrades. We cover the signs an upgrade is due, what an old machine really costs, and how our Smart Upgrade Plan takes you from audit to running system.
What a compressor upgrade actually is
An upgrade is not “buy a new compressor”. It starts with measuring what you have and what it costs to run. Then you replace the right machines, in the right order, with kit sized to your real demand.
Air-Mech offers three levels:
- Efficiency Upgrade. A like-for-like swap focused on energy gains. Newer airends and motors alone typically save 10 to 15%.
- Performance Upgrade. A right-sized unit with a variable speed drive (VSD). On sites where demand goes up and down through the day, this can save 20 to 35%, because the compressor matches its output to what you actually use.
- Optimised System Package. A full redesign of compressors, air treatment, pipework, and controls. On older estates this can cut total compressed air energy costs by 30 to 50%.
All three figures come from the Air-Mech compressor upgrades page, where each level is set out in full.
Signs your compressor is due an upgrade
You do not need a failure to justify a replacement. Watch for these instead:
- Repair bills keep climbing. When yearly repair spend rivals a finance payment on a new unit, you are paying new-compressor money for old-compressor risk.
- The machine runs flat out, or barely at all. A fixed-speed compressor draws close to full power even when demand is low. That gap is pure waste.
- Your site has changed. More production, new machines, or a bigger building mean the compressor was sized for a plant that no longer exists.
- Parts are getting hard to find. Long lead times on spares turn small faults into long outages.
If two or more of these sound familiar, an audit will tell you exactly where you stand.
What an old compressor really costs you
Energy is the big number. Over its life, a compressor’s electricity bill dwarfs its purchase price. A fixed-speed machine that cycles between full load and idle burns money during every low-demand hour. Nights, weekends, and slow shifts all add up.
Then there is downtime. An aged unit fails more often, and it fails without an appointment. If your line stops when the air stops, the true cost of keeping the old machine is not the repair bill. It is the lost output while you wait for parts.
Want a number for your own site? The Air-Mech energy savings calculator gives you a quick estimate before anyone visits.
A real example: Flying Spares
Flying Spares supplies parts for luxury and classic cars. When they moved to a bigger facility, their 11kW fixed-speed compressor could not support the expanded workshop. Air-Mech designed and installed a complete new system around an 18.5kW variable speed screw compressor with an integrated dryer, plus filtration, an aluminium ring main, and hose reels.
The result: nearly double the capacity, yet lower energy use. The VSD system saves 4,322 kWh a year, worth £1,729 a year off the electricity bill, with a five year service plan included.
“The expertise and tailored solutions from Airmech were crucial during our site expansion,” said Andy Thwaites, TSD Manager at Flying Spares. “Their advanced compressed air system not only enhances our operational efficiency but also offers significant energy savings.”
Read the full Flying Spares case study for the complete system spec.
How Air-Mech handles compressor upgrades
The Smart Upgrade Plan runs in five steps.
1. Compressed air audit. We assess every compressor on site: run hours, energy draw, repair history, and remaining life. Each unit is ranked by cost impact and payback. Proceed within 60 days and the audit fee is credited against your order.
2. Design and specification. We size the kit to your actual demand profile. No oversizing, no guesswork. The Design Fit Guarantee means the equipment meets the agreed performance criteria, or we make it right.
3. Finance options. Outright purchase, finance lease over 3 to 5 years, operating lease, or maintenance bundled into one predictable monthly cost. We help you pick what fits your budget.
4. Installation and commissioning. Most upgrades complete with minimal or zero downtime, and we provide temporary air if needed. We hold CompAir L-Series and Hydrovane HV-Series stock at our Nuneaton warehouse for fast delivery, and we remove and dispose of your old kit properly, including oil draining and certified waste collection. A 30 day post-install revisit tunes the settings under real operating conditions.
5. Maintenance bridge. Add an Uptime Protection plan alongside the upgrade and your new equipment is covered from day one.
Air-Mech has done this for 45 years, with more than 100,000 service visits behind us. We are a BCAS member, SafeContractor approved, and an authorised distributor for CompAir, Hydrovane, ABAC, and Champion. And once the new kit is in, our compressor servicing team keeps it efficient for the long run.
Book a compressed air audit
Stop guessing what your old compressor costs you. Book a compressed air audit with Air-Mech on 024 7634 5658. We will measure your system, rank every machine by payback, and give you a clear, phased plan. Proceed within 60 days and the audit fee comes off your order.