Effortless, Effective and Ever So Smart
How today’s sophisticated compressed air master controllers require minimal effort for maximum and on-going energy efficiency gains
* note: this blog was provided by Kaeser. View the original here.
Minimal effort for maximum compressed air supply system efficiency throughout its entire life-cycle. Sound good? In this blog post we discuss how modern smart technology has created a new generation of sophisticated, intuitive and Industrie 4.0-ready master controllers that can effectively and effortlessly assist you in operating an energy optimised compressed air system through its entire life-cycle.
It makes sense that you would want to run an energy optimised compressed air system - after all on average, the energy costs of operating a compressor will amount to around 75% of its total lifetime costs. Operating an efficient system will keep these costs to a minimum. And, of course by reducing your electricity usage you are also reducing your carbon footprint.
For quite a minimal amount of effort, one of the most effective ways to achieve an energy optimised compressed air system is to integrate a sophisticated, intuitive and Industrie 4.0-ready master control system.
Minimal effort, maximum results
So why are the latest generation of Industrie 4.0-ready master compressed air management systems so effective and effortless in optimising compressed air system efficiency? Let’s look at some of the key features of the Sigma Air Manager 4.0 (SAM 4.0) master controller as an example to explain.
Effective
- Identify - in real-time
As the central mastermind of a compressed air system, a master controller such as the SAM 4.0 can control the entire compressed air supply system. It collects, and then via IoT (the Internet of Things), transmits process data in real-time to a centralised application. - Analyse - in real-time
With help from specialised algorithms, the continuous analysis of the transmitted data is subsequently performed.
The algorithms in the Adaptive 3-Dadvanced Control orchestrate the interplay between all components and equipment within a compressed air system. The result - just the right amount of compressed air power is provided to meet the specific needs of the application. This in turn assures maximum efficiency at all times.
The innovative and unique Adaptive 3-Dadvanced Control, continuously analyses the relationship between various parameters (e.g. switching and control efficiency), and proactively calculates the optimum combination from a range of many in order to achieve optimum efficiency. Not only are starts and stops taken into consideration, but so too are idling and frequency converter losses, along with pressure flexibility. Moreover, the compressed air system’s pressure performance value is optimised and average pressure is reduced. - React - in real-time
But, today’s master controllers should not only be capable of activating and deactivating compressors according to demand in order to minimise control-related losses - they should also be able to provide comprehensive monitoring and preventive maintenance features.
Implementing a smart master controller like the SAM 4.0, provides the basis for a new era of intuitive predictive maintenance. Through availability of compressed air system process data and the resulting analysis, it is possible to identify the perfect point in the future when your compressed air supply system should be maintained and serviced. This prevents costly periods of downtime, increases energy efficiency (thanks to monitoring of key parameters) and allows compressed air system performance to be precisely matched according to demand throughout the entire life-cycle of the system. This combination of remote diagnostics and demand-oriented preventative maintenance ensures maximum availability and potentially reduces service costs by up to 30%.
The combination of remote diagnostics and needs-based, preventative maintenance also helps assure maximum compressed air supply dependability.
Effortless
One of the great benefits of such smart technologies like the SAM 4.0, is the ability to access, control and manage your compressed air system from anywhere and at any time. Whether it be your smart smartphone, tablet, laptop or PC - any network capable end device can be used to access, control and manage your system. Quite simply this means that you don't have to physically be standing in front of the SAM 4.0 master controller to access important data as well as control and manage your compressed air system.
What’s more you can see your entire system live in a P&I (pipework and instrumentation flow) diagram. This provides a number of key pieces of information, including real-time alarms and maintenance messages for individual components.
The SAM 4.0 is also a comprehensive solution because it allows you to store and analyse all relevant, energy-related data from your compressed air supply. You can then create specific energy reports on-demand.
Conclusion
When such permanent energy management is implemented together with centralised compressed air system monitoring (for predictive maintenance), minimal effort is required on your part for maximum effectiveness and efficiency of your compressed air supply system throughout its entire life-cycle.
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In our modern world, environmental protection has become more than just a corporate buzzword; it's a genuine priority for businesses that want to do their part for a sustainable future. Many of our customers are actively seeking ways to make their production processes as eco-friendly as possible. One small but powerful action you can take is proper condensate treatment . By managing your condensate correctly, you prevent harmful oil and dirt from entering our waterways, helping preserve the environment for future generations. In this blog, we'll explore what condensate is, why its disposal is a concern, and how Kaeser’s innovative i.CF Aquamat system offers a smart, efficient solution. What is condensate? When air is compressed, moisture from the air naturally condenses into water, and that's where condensate comes from. While it might look harmless, condensate typically carries contaminants like oil residues, dirt particles, and sometimes heavy metals. Left untreated, even small amounts can have serious impacts on the environment. Due to the risk of water pollution, strict environmental regulations prevent businesses from releasing untreated condensate into drainage or sewage systems. That means proper management isn't just a good idea, it’s a legal requirement. What does an Aquamat do? Kaeser’s new i.CF Aquamat range makes condensate treatment easy, effective, and smart. These units are equipped with intelligent controllers that continuously monitor condensate levels. When the condensate reaches its maximum limit, the system triggers a short, controlled burst of compressed air, pushing the liquid through special filter cartridges. Here’s what happens next: Purified water exits the system and is safe to pour into standard drainage systems. Oil and contaminants remain trapped inside the filter cartridges, ready for safe, easy disposal with no direct contact with hazardous waste. This hands-free, automated process ensures environmental compliance without disrupting your daily operations. What are the benefits? The i.CF Aquamat range offers multiple advantages, making it a smart investment for any business: Environmental protection: By treating your condensate before release, you actively prevent harmful toxins from polluting waterways. Cost savings: Since you're safely releasing most of your condensate and only disposing of the small amount of captured waste, you can save up to 90% on disposal costs. Maintenance efficiency: The smart controller sends an alert when servicing is needed, helping you avoid unnecessary maintenance costs and downtime. Modular flexibility: Every model in the i.CF Aquamat range uses the same filter cartridges. That means scaling up or adapting your system is simple and cost-effective as your business grows. Why it matters Treating condensate properly isn’t just about compliance, it’s about responsibility. Every step we take to minimise industrial waste contributes to a healthier planet. With solutions like the i.CF Aquamat, businesses can meet environmental obligations, save money, and feel good knowing they’re part of the solution, not the problem. Ready to find out more about how you can treat your condensate safely and sustainably? Get in touch with our team today, we’re here to help you make a difference.
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Pressure drop occurs every time a filter is put in the line, a dryer is installed, or pipework is run. Having pressure drop across these items means your compressor needs to run at a higher pressure to achieve the required down-stream pressure. You may not realise that a 1 bar increase in compressor pressure equates to a 6% increase in energy consumption. This is money that doesn't need to be wasted. To avoid energy loss from pressure drop, the following points should be considered when designing or replacing a compressed air system: Filters: Every filter installed in the line increases pressure drop. Keep filters to a minimum - but make sure they are the right size and grade. Refrigeration dryers: Refrigeration dryers, especially the cheaper ones, can have quite a high pressure drop - check the value before making the decision. Timing: The most economical time to get your pipework the right size is when it's being installed. It will normally cost about the same amount of labour to go a size larger.
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