Overview
Client: Engineering company
Location: Essex
Industry: Engineering and manufacturing
Solution: Compressed air energy audit, leak reduction, pressure optimisation and upgrade to Avelair variable speed air compressors
An established engineering company in Essex approached Avelair to reduce rising energy costs and improve the reliability of its ageing compressed air system. Following a detailed on-site assessment and performance logging, Avelair delivered a clear strategy to increase efficiency, reduce waste and future-proof operations.
The challenge
The company was operating with 10-year-old fixed speed air compressors that were:
- Consuming excessive electricity
- Running at unnecessarily high system pressure
- Suffering from increasing breakdowns and repair costs
- Causing uncertainty around long-term maintenance budgets
Compressed air is widely regarded as the fourth utility. In engineering environments, it is critical to daily operations. However, inefficient systems can quietly erode profitability through wasted energy and air leaks.
The business required measurable improvements, cost certainty and expert guidance on compliance and system performance.
The solution – Data-led optimisation and modern VSD technology
Step 1 – System monitoring and analysis
Avelair installed energy monitoring equipment to log pressure and air demand over a full week. The detailed report identified:
- Significant air leaks within the pipework
- Excessive system pressure
- Inefficient compressor operation
This data-driven approach ensured all recommendations were evidence-based and financially justified.
Step 2 – Efficiency improvements
Following analysis, Avelair implemented:
- Targeted air leak reduction
- System pressure optimisation
- Upgrade from fixed speed units to new Variable Speed Drive (VSD) air compressors
The new Avelair compressors, manufactured in Bury St Edmunds, Suffolk, were supplied with a comprehensive five-year warranty. This provided the client with predictable servicing costs and eliminated the risk of unexpected repair bills.
The results
Reduced energy consumption
The introduction of VSD air compressors allows motor speed to adjust to real-time air demand, significantly reducing electricity usage.
Lower operating costs
Leak reduction and pressure optimisation immediately improved system efficiency, cutting wasted energy and lowering overall running costs.
Increased reliability
Replacing ageing equipment reduced breakdown risk and improved operational continuity.
Budget certainty
The five-year compressor warranty (and eight-year airend warranty) provided confidence and accurate financial forecasting for maintenance.
Ongoing compressed air support in Essex and East Anglia
Beyond installation, Avelair provides comprehensive compressed air system support across Essex and East Anglia, including:
- Energy efficiency consultancy
- Leak detection and system design optimisation
- Guidance on compliance with Pressure Systems Safety Regulations 2000
- Advice on air quality requirements for engineering, food and breathing air applications
As a long-standing member of the British Compressed Air Society, Avelair operates in line with industry best practice, ensuring every compressed air system is safe, compliant and efficient.
Looking to improve your air compressors in Essex?
If your engineering or manufacturing business in Essex is operating ageing or inefficient equipment, Avelair can deliver a fully monitored, data-led solution to reduce costs and improve reliability.
Contact our team on 01359 282828 to arrange a compressed air assessment and discover how much your system could save.
Posted on:
February 25th 2026