mb air systems ltd
mb air sys-
Th e Facts
Compressed Air: The Facts
Why an iceberg?
A compressed air system can be viewed in a similar way to
The iceberg helps illustrate the hidden cost of your
compressed air system.
The visible area represents the initial equipment purchase
and routine servicing and maintenance.
Hidden beneath is the ever increasing & uncontrollable
We at mb air systems, continue to strive to reduce your
energy usage, by utilising innovative products and solutions
According to the British Compressed Air Society; “Electrically
driven compressors are a major user of energy, accounting
for around 10% of electricity costs in the industrial sector”.
This could be over 10,000 GWHr of electricity.
in today’s terms, this equates to almost £1 billion per year.
mb air systems ltd, with over 40 years of expertise, specialise in compressed air systems and all associ-
ated engineering services.
We carry out detailed compressed air system surveys and provide our clients with innovative and
practical solutions which maximise their plant uptime and minimise their energy and operational costs.
The Iceberg Analogy - 10 year lifecycle costs
Air generation is often the
highest cost for industry
On average, air leaks equate
to around 30% of compressed
Many systems run at a higher
pressure than is required!
For every 2psi reduction in
pressure, 1% of energy costs
can be saved
approximately 90% of the
energy a compressor
generates is waste heat
Most of the time this is not
Obsolete equipment & filters
can purge air and create
pressure drops unnecessarily
The compressor in place may
not be the right choice or size
for the application
The Standard for Audits
DipCam (Diploma in Compressed Air Management)
All calculations / recommendations will be approved by an engineer with a certified diploma in
compressed air management from the British Compressed Air Society.
To ensure that we can meet the needs of industry and be confident in establishing energy saving and
operational opportunities, we regularly participate in approved training schemes from equipment
manufacturers, industry bodies and external training providers.
mb air systems have demonstrated compliance with, and sound management of, current basic health
and safety legislation through accreditation within the Contractors Health and Safety Assessment
Scheme (CHAS) and the Achilles Verify assessment and audit process.
Membership of British Safety Council and the British Compressed Air Society ensure mb air systems
keep up to date with all current legislation, industry guidance and best practice
ISO 11011 (2013) - Compressed Air Energy - Assessment
ISO 11011:2013 sets requirements for assessing and reporting on the performance of the complete
compressed air system from generation, transmission and demand.
The standard sets requirements for analysing the data from the assessment, reporting and
documentation of assessment findings, and an estimate of energy saving resulting from the
It identifies the roles and responsibilities of those involved in the assessment activity.
MB Air Systems have been endorsed by BCAS (The British Compressed Air Society)
for auditing in compliance with ISO 11011!
Training & Certification
SUPPLY TRANSMISSION DEMAND
To Improve, we must measure......
Alongside our experience and expertise, mb air systems ltd has invested heavily in recent times to
ensure that we have the most comprehensive and up to date methods to measure energy, air
consumption, system performance and viability.
Our approach is tailored to suit each customers site.
We utilise a data logger to measure the power consumed by each compressor, while at the same time
measuring the system pressure downstream.
This helps to analyse the load or demand profile of your system. With this information, we can assess,
advise and recommend improvments to the system control strategy
Your pipework system is the transmission that carries the air to your equipment.
More often than not, poor system design or the addition of extra air lines can cause pressure drops,
restrictive flow and can corrode over time. This makes the system less efficient and can mean your
compressor works harder. We can map out your current system, noting areas for improvement,
identify savings and advise on any health and safety implications.
Leaks can be one of the biggest costs to a systems efficiency.
We utilise ultrasonic leak detector to identify the source of leaks in your system.
The resulting report shows the location, estimated size and cost of the leaks.
We can provide costs for repairing each issue and reducing wasted energy.
As compressors age, their output can decline.
We can provide reporting based on a “non intrusive” flow meter that can accurately determine
how much output you are actually getting from your system, without the need for large capital expense
or down time to install.
The heat profile of a compressors components can be a tell tale sign of a compressors condition.
If certain components wear, they can produce excess heat, not perform their fuction as efficient and
lead to the breakdown of other component parts in the system.
We use a specialised thermal imaging camera to display and report this.
Control strategy can be the difference between an efficient system and a wasteful one.
Our aim is to turn compressors off where possible and match the systems output to your demand.
Utilising pressure profiles and system isolation is key to optimising system efficiency.
We can implement remote monitoring solutions to ensure that you can access your compressors information
from anywhere, through a pc, tablet or mobile phone with an internet connection.
This allows tracking and recording, as well as the production of reports when you need them.
We have invested in our service capabilities to allow us to ensure that your system is running as it should
and as efficiently as possible.
As part of our regular servicing agreements, we provide vibration monitoring and oil analysis to identify
problems before they arise and allow remedial action to take place before equipment breaks down.
By December 2015, all businesses which have more than 250 employees or a turnover exceeding €50m,
must conduct a mandatory assessment and report on their energy usage.
We can provide a detailed breakdown of costs associated with your compressed air system to aid with the
Case Study - Large Manufacturing Plant
A large manufacturer based in the UK which produces large volumes of insulation for the
construction and home improvement markets.
They have a diverse mixture of compressor types and technologies, from the last 50 years. This
includes oil lubricated rotary screw and low pressure two stage piston compressors, from a variety of
The client had identified their compressed air as a priority for review as it is one of the biggest
expenses within their process.
Mb Air Systems Ltd was invited alongside others to layout an action plan which would analyse the
compressed air system within the plant. Utilising the ISO11011 assessment process, MB Air Systems
were asked to present our findings to the energy and engineering team, along with recommendations
on energy savings, future improvments, health and safety advice and future proofing the plant as
they continue to grow.
The preliminary report we provided gave clear indication of current energy consumption that the
compressed air system was using, alongside a site overview that identified areas that should be
In the following weeks, we carried out a full site review which included the following;
Air quality analysis which determined that the main dryer on site was not drying the air properly. We
recommended this be turned off to save on purge air. This gave the client an immediate annual
saving of £30,000.00, without the need for capital outlay
- A full ISO 11011 compliant report was completed which mapped out all compressed air assets,
defined their performance and energy profiles, the transmission pipework system and identified
control measures which should be applied to the
demand side of the system
- Thermal imaging was carried out and reports submitted
on all assets to show condition and requirement for
replacement of degraded components
- Recommendations were made to replace some of the
ageing inefficient equipment with modern energy efficient
In conclusion, we identified that the site could reduce annual energy costs on their compressed air
system by £110,284.00, 23% and maintenance costs by approximately £50,000, 53% based on our
149 Glasgow Road Wellheads Road
Wishaw Farburn Industrial Estate
Lanarkshire Dyce, Aberdeen
ML2 7QJ AB21 7HG
Tel 01698 355711 Tel