Overview
Client: Engineering company
Location: Braintree, Essex
Industry: Engineering and manufacturing
Solution: 18.5kW variable speed rotary screw air compressor with system data logging and optimisation
An established engineering business in Braintree required a more efficient compressed air solution to match fluctuating production demands. Following detailed data analysis, Avelair supplied and installed a new 18.5kW variable speed rotary screw air compressor, improving performance while reducing energy waste.
The challenge
The existing compressed air system relied on a fixed speed compressor. While operational, it was not optimised for the site’s varying air demand.
Avelair conducted a full data logging assessment of the system. The findings showed air consumption fluctuating between 30 and 94 cfm – a clear indication that a variable speed solution would deliver significant efficiency gains.
Operating a fixed speed compressor under variable demand conditions can lead to:
- Excessive off-load running
- Unnecessary energy consumption
- Wider pressure bands
- Higher long-term operating costs
The client required a more responsive system without compromising reliability.
The solution – Intelligent variable speed control
Avelair installed a new 18.5kW VSD rotary screw air compressor, precisely matched to the site’s air demand profile.
Key system benefits:
- Inverter-driven motor control – Adjusts speed in real time based on air usage
- Reduced off-load running – Minimises wasted electricity
- Tighter pressure control – Maintains pressure within ±0.1 bar
- Improved energy efficiency – Delivers measurable cost savings
The existing Avelair fixed speed compressor was retained on site as a backup unit, ensuring resilience and continuity of supply.
The results
Lower energy consumption
The new VSD compressor automatically ramps motor speed up and down in line with production demand, significantly reducing off-load losses.
Improved pressure stability
Maintaining a narrow pressure band improves system efficiency and supports consistent engineering processes.
Greater operational flexibility
The site now benefits from a compressed air system that adapts to production patterns, rather than operating at a constant, inefficient output.
Increased reliability
By keeping the previous unit as a standby compressor, the client has enhanced system redundancy and reduced downtime risk.
Supporting air compressor efficiency in Braintree and across Essex
This installation reinforces Avelair’s reputation as a trusted supplier of air compressors in Braintree and throughout Essex. Through data-led analysis and carefully specified equipment, businesses can unlock substantial energy savings while improving reliability.
Avelair provides complete compressed air consultancy, including system monitoring, performance analysis and long-term maintenance support across East Anglia.
Looking for a variable speed drive air compressor in Essex?
If your business operates with fluctuating air demand, a variable speed compressor could significantly reduce your energy costs.
Contact Avelair on 01359 272828 to arrange a compressed air assessment and discover how much your system could save.
Posted on:
February 25th 2026