Flow Monitoring for Air Compressors
Save Energy, Reduce Costs, and Prevent Breakdowns
Did you know that compressed air systems can waste up to 30% of energy through undetected leaks?
Flow monitoring for air compressors gives you real-time insights into your system. Often called the 'fourth utility' alongside electricity, water, and gas, compressed air is one of the most expensive resources an industrial facility generates, and it often goes unmonitored. This allows you to spot inefficiencies, quantify your leakage rate, prevent costly breakdowns, and reduce your bills.
Control Gear delivers flow monitoring solutions and complete air compressor flow management systems across South Wales and the West, including Cardiff, Newport, Swansea, Bristol, Stroud and Swindon.
Why Monitor Air Compressor Flow?
Compressed air accounts for around 10% of industrial electricity consumption, costing around £0.02 per cubic metre of air generated. Without monitoring, you could be wasting thousands of pounds a year. Across UK industry, this waste translates to a financial loss of over £2.6 million every single day.
Benefits of Air Compressor Monitoring Systems
- Energy Savings – Identify and eliminate waste. Most systems have the potential to save up to 30% on electricity
- Leak Detection – Use real-time data to find and fix costly leaks fast. A single 1.5 mm leak can cost over £2,000 per year.
- System Optimisation – Use data on your air demand profile to get your compressors running at their best and avoid inefficient 'unloaded' running.
- Predictive Maintenance – Monitor the status of your compressed air equipment to spot anomalies before they cause a shutdown, extending the life of your compressor.
- Guarantee Air Quality – Ensure the quality of air by monitoring key parameters like dew point, crucial for food, pharma, and electronics manufacturing.
Complete Monitoring and Control of your Compressed Air Monitoring Systems
Even small leaks can cost your business thousands of pounds a year. A 1/4 inch leak at 100 pounds per square inch (psi) can cost over £6,000 annually. A flow monitoring system pays for itself in 6–12 months through energy savings alone. Below are some common air compressor problems you can avoid when you have complete control via a flow monitoring system.
| Problem | Cause | Risk | Solution |
|---|---|---|---|
| Low CFM (cubic feet per minute) Output | Clogged intake air filter, leaks, worn compressor | Machines do not work properly, production slows down | Regular filter cleaning and flow measurement to check air delivery and volumetric flow |
| High Energy Bills | Poor compressor efficiency, air leaks, wrong-sized system | Wasting money every month. This is often caused by 'artificial demand' - the volume of air wasted by leaks, which forces compressors to run longer and at a higher pressure just to compensate. | Flow monitoring to track the consumption of compressed air, fix leaks, and correctly size your system. |
| Water in Air Lines | No dry air dryer, bad dew point | Rusty tools, damaged products, shorter equipment life | Install proper dryer, add dew point sensor monitoring |
| Inconsistent Pressure | Leaks, improper sizing, high air consumption | Product quality issues, machine damage | Monitor compressed air flow rateand pressure loss across the system, right size your system. This prevents operators from incorrectly increasing the compressor discharge pressure above the required operating pressure, which only wastes more energy. |
Our Flow Monitoring Solutions
Control Gear offers custom airflow monitoring packages based on the right types of flow meters to fit your business and air compressor system.
Advanced Flow Meter Technology
We supply and install industry-leading monitoring equipment:
- Thermal Mass Flow Meters – The standard for energy management. These meters measure mass flow directly (e.g., in SCFM or $Sm^3/h$) without needing pressure compensation. Their high accuracy and excellent sensitivity at low flow rates make them ideal for measuring leak loads.
- Ultrasonic Air Flow Meters – Available as non-invasive 'clamp-on' models. These can be installed on the outside of a pipe with no downtime, making them a perfect solution for surveys, diagnostics, or critical systems that cannot be shut down.
- Differential Pressure Meters – A traditional technology (like an orifice plate) used for basic monitoring. While inexpensive, they can create a permanent pressure loss (wasting energy) and have poor accuracy at low flow rates.
- Dew Point Sensors – detect when air is about to form water droplets, helping prevent equipment damage and extend machine life. This is critical for quality control, ensuring your air treatment (dryers, filters) is working effectively to protect your final product.
What does a monitoring system include?
- Instant alerts for pressure drops, leaks and unusual usage patterns
- Historical trend analysis to optimise compressor scheduling and improve the performance of your system
- Energy efficiency tracking with detailed savings reports to verify your ROI
What Sets Control Gear Apart: Expert Service
Our comprehensive approach ensures that you get the most out of your flow monitoring investment. As authorised Atlas Copco partners, we provide expert SMARTLINK installation, setup, and ongoing support to maximise your compressor performance.
1. System Audit
Our engineers will conduct a full assessment of your existing compressed air system, often following the framework of an ISO 11011 energy audit:
- Full system pressure testing
- Current energy consumption analysis using non-invasive data loggers to capture a true load profile
- Air quality assessment
- Comprehensive leak detection survey
2. Customised Monitoring Solution
Based on your specific requirements and audit findings, we will design a monitoring package that:
- Transforms raw compressor data into actionable intelligence
- Integrates with your existing equipment
- Scales with your usage
- Provides the data you need to achieve your business goals
- Fits your budget
3. Installation and Training
Our certified technicians will:
- Install all monitoring equipment with minimal downtime
- Calibrate systems for accurate readings
- If required, integrate data with your existing SCADA or BMS platforms
- Train your staff on dashboard usage and data interpretation
- Provide full documentation and support materials
4. Ongoing Support and Maintenance
We do not just install and leave:
- Regular system check-ups and recalibration
- Software updates and technical support
- Quarterly efficiency reports with actionable insights to ensure savings are sustained and new opportunities are identified
- Proactive maintenance recommendations
SMARTLINK is like having a 24/7 expert watching your air compressor system
This remote monitoring service connects to your compressed air equipment (like a rotary screw GA VSD+ or ZT series oil-free compressor) and sends real-time data to you and our service team.
SMARTLINK is available in different levels to suit your needs:
- SMARTLINK Service: Provides a service timeline and digital logbook.
- SMARTLINK Uptime: Delivers real-time alerts to prevent downtime.
- SMARTLINK Energy: Offers detailed reports to track energy efficiency.
For a complete picture, this can be combined with SMART AIRnet sensors, which extend monitoring into your pipework to measure flow and pressure at the point of use.
Stop problems before they cause downtime
Real-Time Alerts - instantly notify you about air leaks or pressure drops.
Ensure you get the air flow you need
Performance Tracking - measures CFM output and air delivery constantly.
Avoid unexpected repairs and production shutdown
Predictive Maintenance - identifies potential issues before they cause breakdowns.
Detect efficiency issues that waste money
Energy Monitoring - tracks exactly how much power your compressor uses.
Control Gear Quality Guarantee
Industry-leading certifications back our commitment to excellence:
- Environmental Management – ISO 14001
- Quality Management – ISO 9001
- Occupational Health and Safety – ISO 45001
- All engineers are F-Gas certified
We offer Guardian Service, our industry-leading service plan that provides fixed annual service and warranty coverage for up to 9 years with no hidden costs.
Frequently Asked Questions
How do I know if my compressed air system needs flow monitoring?
If you are experiencing pressure fluctuations, high energy bills, or frequent breakdowns, flow monitoring will identify the root cause. Most customers achieve 15–30% energy savings.
Will installing flow meters disrupt our operations?
Most modern flow meters can be installed with minimal disruption. Our ultrasonic and clamp-on options require no system modifications and can be fitted during normal operation or scheduled maintenance breaks. Even inline meters like thermal mass can be installed via a 'hot-tap' method, which also prevents a shutdown.
Can flow monitoring integrate with our existing building management system?
Yes. Our solutions are compatible with all major BMS, SCADA and PLC systems. We can output data via Modbus, 4-20mA, or other protocols to ensure seamless operation and data sharing.
How quickly will I see a return on investment?
Through energy savings, most customers see a full return within 6–12 months. Systems with significant undetected leaks often see payback in as little as 3 months.
Why Work With Us?
