Reducing Compressed Air Production Costs with FLOWBOX EMOS
Smart Compressed Air Management: Cost Savings and Seamless Operations
Challenge: Inefficiency and High Costs in Compressed Air Production
Compressed air systems are often plagued by inefficiencies such as improperly sized compressors, cycling issues, unexpected downtimes, or technical malfunctions. Without detailed operational and cost data, these problems are difficult to identify— leading to excessive energy expenses, unnecessary equipment wear, and increased risk of system failures. The solution lies in a combination of technology upgrades and intelligent production management. The first step involves modernizing the equipment—such as upgrading to variable-speed compressors (with inverters) that allow for smoother, more energy-efficient performance. This is followed by implementing a smart control system like FLOWBOX EMOS, which ensures automation and real-time monitoring.
Smart Automation and System Optimization with FLOWBOX
Real-Time Cost Tracking per Cubic Meter of Compressed Air
FLOWBOX provides a detailed, real-time breakdown of production costs, segmented by each production line and individual compressor.
Detection of System Inefficiencies
Automatically identifies issues such as compressors that are oversized or undersized, which can lead to cycling and unnecessary energy losses.
Automatic Compressor Switching and Pressure Hysteresis Management
FLOWBOX dynamically switches between compressors based on current load and optimizes pressure hysteresis. This ensures balanced equipment usage and consistent system operation.
Continuous Monitoring and Instant Notifications
The system continuously monitors all compressors and connected devices. It automatically detects failures, overloads, cycling patterns, or other technical issues—and instantly alerts responsible personnel.
Outcome: Lower Costs, Fewer Failures, Smooth Operations
With FLOWBOX EMOS, businesses achieve significant cost savings in compressed air production, reduce equipment wear and tear, and prevent system failures. The result is a stable, efficient, and reliable compressed air system tailored for modern industrial needs.
