Skipping Air Compressor Maintenance? The Real Costs Are Higher Than You Think

Why Your Air Compressor is a Critical Asset

Compressed air is just like any other utility, such as electricity, gas and water. Its use in the UK industry is pervasive, and since it is manufactured on site, maintenance may be neglected. Avoiding scheduled service can lead to costly downtime and maintenance.

In addition, the TCO (Total Cost of Ownership) of a compressor may be a surprising factor. For example, the purchase price usually represents 10-20% of the lifetime cost, and 70-80% is typically energy. Maintenance has a direct impact on the energy figure.

Unplanned Downtime and Production Delays

The most immediate result of a critical compressor failing is the shutdown of production. Unplanned production stoppages are estimated to cost British manufacturers £180 billion a year, with individual breakdowns costing thousands of pounds in lost orders.

A planned service schedule is designed to prevent that from happening. This maintenance combines pre-arranged service visits, the use of OEM parts and high-tech diagnostics to predict potential faults before a complete stoppage occurs.

The Higher Cost of Emergency Repairs

Reactive maintenance is more costly than planned servicing. Additional fees that are typical with emergency call-outs are as follows:

• Increased Call-Out Fees: Prices for same-day, unscheduled service calls are often higher than for scheduled visits.
• Premium Labour Rates: Overtime work is commonly charged at a premium rate.
• Ancillary Costs: Expenses for expedited parts and temporary equipment rental add to the final bill.

The Flaw in Reactive Repairs

A consequence of reactive repairs is increased total costs. Reactive repair does not necessarily improve the system’s efficiency, nor does it guarantee that failures will not recur. Fixing only the problem at hand may not address the cause.

Increased Energy Consumption

Neglected compressors often become a hidden cost on energy bills. A poorly maintained system can lose up to 30% of the compressed air it generates to leaks.

This waste has a direct financial impact. One manufacturer in Wales, for example, reduced annual energy costs by £36,000 after a leak detection survey identified 40 leaks. An ultrasonic Compressed Air Leak Detection service can identify these leaks efficiently. Similarly, technologies like Variable Speed Drive (VSD) compressors are designed for energy efficiency, but their benefits are diminished if the system is not properly maintained.

Systemic Operational Damage and Asset Depreciation

A compressor with degraded filters and separators can send water, oil and particulates into the air network. This contamination can corrode pipework and damage downstream pneumatic equipment.

A significant consideration for certain industries is air quality. The food and beverage or pharmaceutical sectors, for example, must ensure a high quality of air. This is done through maintenance of filtration systems and the use of equipment such as oil-free compressors. You can learn more about Why is Compressed Air Quality Important?.

Poor maintenance also shortens the operational life of the equipment. A compressor’s lifespan is measured in running hours, and neglect can reduce it from over 10 years to as few as three, requiring a premature capital investment. Following a proper service schedule is key; you can learn How Often Should You Service an Air Compressor?.

The Legal Imperative: PSSR 2000 Compliance

Periodic inspection and testing is a legal requirement for the majority of industrial systems. The Pressure Systems Safety Regulations 2000 (PSSR) cover all systems containing a pressure vessel of over 250 bar-litres.

Failure to comply with PSSR can have serious consequences. HSE prosecution, large fines and invalidated insurance are just some of the things that could happen. Maintenance logs, service reports and a Written Scheme of Examination (WSE) all help to provide evidence of due diligence if an HSE inspection takes place.

The Value of Preventive Maintenance

It’s a common misconception that putting off maintenance work is a way of saving money. In fact, it can cost you dearly through downtime, energy costs and compliance fines. Proactive maintenance should be an operational best practice that ensures your compressed air system is productive, efficient and safe. Read more about The Importance of Regular Air Compressor Servicing.

Partnering with an Expert Provider

Partnering with an expert maintenance provider means your compressed air system will be running smoothly and meeting compliance standards. Control Gear offers comprehensive system audits, including scheduled servicing, full system audits, and legally mandated PSSR examinations. Our qualified engineers can ensure your equipment is well-maintained and up to the manufacturer’s standards, so you are always audit-ready.

• Book your PSSR-compliant maintenance inspection to ensure you are audit-ready.
• Schedule a no-obligation leak detection survey and start cutting your energy costs.