Heiko Fleischhacker: Energy efficiency is crucial for the competitiveness and sustainability of any company. However, when looking at compressed air systems, I always notice that the focus is often only on power consumption. Many companies already focus on energy-efficient lighting or photovoltaics, but the potential in a compressed air system is often overlooked.
When looking at energy efficiency in compressed air, they usually only consider the compressors. Discussions about high costs often centre on compressed air generation. However, the entire compressed air system, from generation to the use of the compressed air, must be analysed. Having a partial view means that valuable savings potential goes unrealised.
Heiko Fleischhacker: Producing, distributing and processing compressed air energy efficiently is complex. Although many customers are specialists in their own production processes, they have only limited knowledge of the compressed air systems they use. In my experience as an auditor, many customers don't know which adjustments they need to make in which order to achieve a sustainable increase in efficiency. Energy management and maintenance staff often lack the necessary expertise in pneumatics. Optimising compressed air is more than just eliminating leakages. It requires broad technological expertise and a thorough understanding of the compressed air system, from the compressor station to the pneumatic application. For example, a few weeks ago I carried out an audit at an established pharmaceutical company. The compressed air they produced was of a very high quality. But they never asked themselves if this was actually necessary for the production process. By making a small adjustment to the compressed air quality, we achieved extremely quick and sustainable energy savings. This shows once again how important it is to have a complete overview of the compressed air system, the compressed air requirements and an in-depth understanding of pneumatics.
Heiko Fleischhacker: A compressed air energy efficiency audit is an overall assessment of a company's compressed air system, from the compressor room to the pneumatic application. The goal of the audit is to identify areas where usage is inefficient and propose ways to save energy. This should reduce costs and CO₂ emissions, which in turn will increase productivity and improve sustainability. The audit provides a company with valuable insights and answers in several key areas. It shows how efficiently the compressed air is generated, how well the company's own compressors are utilised and how effectively the compressed air is routed through the system. It also identifies potential for improving infrastructure.
At the same time, the audit provides important information about the compressed air quality. This is crucial in order to meet production requirements and ensure machines perform reliably. The audit also shows how efficiently the compressed air is utilised in the various applications. At the end, companies receive a detailed report with precise data and prioritised recommendations for action that can be used to optimise the entire compressed air system. This final report, including all measurement results, can be used for energy management in accordance with ISO 50001.
Heiko Fleischhacker: I always advise companies that want to optimise their compressed air systems to take a structured approach. Because the various components are directly dependent on one another, a comprehensive assessment of the compressed air system is incredibly importance. Selective changes at one point always have an impact on the performance and efficiency of the overall system. An optimally sized compressor station loses its efficiency benefits if leakages and inadequate compressed air preparation cancel out these advantages.
In simple terms, the energy efficiency of a compressed air system can only be successfully controlled using an all-encompassing approach. A compressed air energy efficiency audit will provide you with the necessary information to do this. And, just as importantly, you also get a clear recommendation on which optimisation measures should be taken and in which order.
Heiko Fleischhacker: An audit always makes sense if a company wants to get an impartial assessment and a precise analysis of the current condition of its compressed air systems. I recommend that companies undergo an audit to assess their compressed air systems, particularly in the context of DIN ISO 50001. This will allow them to comply with the legal and normative requirements in a very specific and economical manner. At the same time, the company's own energy efficiency can be continuously improved. In addition, we are getting an increasing number of enquiries from companies who want to find out more about the energy efficiency of their updated machines and systems before and after major changes. For example, when installing new compressors or setting up new production lines. In both cases, an audit provides an excellent foundation for improved operational efficiency. There are clear indications of where the reliability of the systems can be increased, and often with simple means.
Heiko Fleischhacker：压缩空气能效审计在 Mativ Inc 旗下一家公司取得的成效就是个很好的例子。这家公司的压缩机布设尺寸错误，而且缺少上级压缩机控制器。通过改造，我们大幅提高了压缩机的精确度，使其工作时间能够根据实际气压需求进行精准调整。压力调节和能源效率都实现了可持续改善。此外，这些调整还降低了压力波动风险，使系统性能更加稳定。通过系统性消除泄漏，我们还发掘出更多节约潜力。而所有这些措施都有助于实现可持续改善， 不但能降低能源成本，还可延长设备的使用寿命。
Heiko Fleischhacker：是的，当然！维护和维修成本往往与压缩空气系统设计不当有关。在我们执行过的诸多审计中，我发现，只要使用得当，机器的使用寿命绝对能超过 20 年。但是一旦布设错误，机器的使用寿命可能只有 5 年。在审计框架下有针对性地进行优化和定期检查，不但能避免因开发导致高昂支出，还能显著改善设备的整体性能。
Heiko Fleischhacker：审计结果必须得到企业的信任，让客户相信审计结果真实、公正地反映了系统和流程的情况。在这种前提下，保持中立至关重要，因为会直接影响审计结果的可信度和认可度。保持中立是我们这些认证审计员必须履行的义务。这意味着我们要独立、客观地进行审计，不能代表任何个人或企业利益。因此，我们非常重视遵守 DIN ISO 11011 标准针对压缩空气系统能源审计工作规定的具体要求。
Heiko Fleischhacker：我们在气动和电气自动化领域拥有多年专业经验，因此备受客户青睐。早在单个组件开发阶段，我们就非常重视能效问题。但是对我们的客户来说，全方位检查企业的整套系统更有益处—— 在此过程中，不但能发掘节约潜力，还能为更高效地使用压缩空气开发合适的解决方案。Festo 节能服务为感兴趣的企业提供定制服务， 从分析当前现状，到为压缩空气系统和设备现场提供解决方案建议和具体优化措施，不一而足。
Heiko Fleischhacker：能源效率始于机器和设备的设计与规划阶段。重要的是了解阀的最佳位置，以及软管截短或延长对能耗有无影响。因此我认为，企业从一开始就看重长期节能潜力这一点很重要。比如，装有集成式止回阀的机器购置时可能价格更高一些，但却能在生命周期内，凭借卓越的节能效果快速抵消较高的购置成本。Festo 从项目初期就为客户提供全面的建议。此外，我们还使用先进的模拟工具和数字规划工具，确保系统配置高效且可满足未来需求。借助详细的早期规划，我们在客户开发高性能、高能效系统时为其提供支持。
感谢 Heiko Fleischhacker 围绕生产企业压缩空气能效审计的意义和执行问题提供的广泛信息与宝贵见解。他在专业知识和丰富经验基础上，向我们阐述了企业如何通过压缩空气系统整体审查实现显著节能和能效提升。