JHF helps you maximize efficiency where it matters most. With our compressed air demand analysis, you can improve performance and reduce waste. We evaluate your system’s point-of-use applications, identify unnecessary consumption, and provide pressure drop solutions that maintain output while lowering energy use. From air flow optimization to selecting energy-efficient air tools, our demand-side improvements help you get the most from your compressed air investment.
Air Leaks
Air leaks are one of the most common and costly sources of energy waste in compressed air systems. Even minor leaks from fittings, valves, or hoses can lead to significant losses over time, forcing compressors to run more frequently and for longer durations. Routine leak detection, tagging, and timely remediation are essential to maintaining system efficiency. Using ultrasonic leak detectors and implementing a structured leak management program can greatly reduce waste and improve overall system performance.
Inappropriate Uses of Compressed Air
Compressed air is often used for tasks it’s not suited for, such as cooling workstations, sweeping floors, or powering tools that could be run electrically. These inappropriate uses increase energy demand without adding value and reduce the capacity available for critical operations.
By replacing these uses with blowers, electric tools, or vacuum systems, facilities can reduce compressor load, lower energy costs, and extend equipment life. A comprehensive audit can help identify and eliminate these inefficiencies.
Pressure Drop
Excessive pressure drop occurs when air loses pressure as it moves through the system, often due to undersized or poorly laid-out piping, dirty filters, or excessive distances between the compressor and point of use. This drop forces compressors to work harder to maintain desired pressure levels, resulting in increased energy consumption and reduced system lifespan. Regular maintenance, proper piping design, and replacing clogged filters help minimize pressure drop and maintain efficient airflow throughout the system.
Point-of-Use Equipment
The tools and devices that use compressed air, like cylinders, actuators, and pneumatic tools, play a critical role in overall system efficiency. Inefficient or outdated equipment can consume more air than necessary, creating excess demand.
Optimizing point-of-use equipment involves evaluating tool performance, using air tools rated for efficiency, and ensuring proper flow regulation. Adding features like local regulators and shut-off valves helps reduce unnecessary air consumption and improves control.
Flow Regulation & Control
Uncontrolled airflow can lead to over-pressurization, energy waste, and unnecessary wear on tools and systems. Installing pressure regulators, flow controllers, and automatic shut-off valves helps match airflow to actual demand, especially during idle periods or low production hours. These controls maintain consistent pressure at the point of use without overloading the entire system. With proper flow regulation, you can improve energy efficiency, extend equipment life, and avoid fluctuations that reduce process reliability.
Air Storage and Receiver Sizing
Properly sized receiver tanks play a vital role in stabilizing pressure and managing demand fluctuations in a compressed air system. Undersized or poorly placed air storage can lead to frequent compressor cycling, reduced system efficiency, and pressure instability at the point of use.
Assessing whether your primary and secondary receivers are correctly sized helps ensure sufficient buffering during peak demand and compressor transitions. A well-designed storage strategy improves system responsiveness, reduces energy use, and protects compressors from unnecessary wear.
Production Scheduling & Demand Events
Short bursts of high air demand, such as from machine startups or simultaneous tool use, can cause pressure drops and excessive compressor cycling, leading to energy waste and system strain. Identifying these events through air audits or monitoring tools allows for smarter system control.
Using demand valves, load/unload controls, or strategically placed air storage can help smooth out demand spikes. Aligning compressed air production with actual usage patterns and scheduling can significantly reduce peak loads and improve overall system efficiency.
Condensate & Moisture Management
Moisture in compressed air systems can lead to corrosion, flow restrictions, equipment damage, and product contamination. Proper condensate management—including functioning dryers, filters, and automatic drains—is essential to maintaining air quality and system reliability.
Regularly inspecting and servicing point-of-use dryers, moisture separators, and drain valves ensures water is effectively removed before it can cause problems. A well-maintained moisture management system contributes to longer equipment life, improved productivity, and reduced maintenance costs.