3 costs to evaluate when selecting a new compressor

Did you realise, that on average the capital investment cost of a compressed air system is only 18% of its total lifetime costs? When comparing new compressor quotes it is therefore imperative that the costs that make up the further 82% should also be closely considered. 

1. Energy Cost; accounting for up to three quarters of lifetime costs, energy is by far the largest cost attributed to running a compressed air system.
   The energy costs of any given compressed air system will vary depending on a number of factors including; the kW size of the compressor(s) in the system, the demand for compressed air (e.g. how often the compressor is run) and the electricity rates. In addition, there are variances in compressor efficiency between different types of compressors (e.g. fixed speed versus variable speed) as well as different brands of compressors. In comparing quotes for new compressors, it is therefore important that you are comparing apples with apples e.g. the same kW sized compressor or the same compressor technology.
   
   
2. Maintenance Costs; following the prescribed maintenance schedule and opting for original equipment manufacturers consumables will play a key role in ensuring that a compressed air system operates at its peak performance at all times and provides maximum production reliability.
   On average, maintenance work is estimated to account for around 7% of a compressed air systems lifetime costs. Keeping both of these facts in mind, it is essential to investigate the recommended maintenance schedules and costs of servicing the new compressor, as well as the local availability of spare parts, qualified Service Technicians and the cost of breakdowns or emergency service.
   
   
3. Installation Costs; whilst the installation cost of a compressed air system is only around 2% of its lifetime costs, the choices made around the overall installation could heighten these costs unnecessarily. For example, the choice of piping could impact the installation time, with certain types of piping being more labour intensive to erect. In addition, certain types of piping may be cheaper to install, but are more prone to leaks and other inefficiencies leading to higher operating costs over time. 

Another consideration is the size of the compressed air system and its location. This will impact the duty cycle and heat load on the compressor - factors which will greatly influence equipment longevity. 

There are further variables that should also be considered when assessing installation costs, for example, the sound pressure level of the compressor. Noisy compressors may require additional sound proofing, or even their own room to keep the noise levels comfortable at point of use, all adding additional costs. 

Aside from considering the purchase price and the lifetime costs in selecting a compressor, it is also worth considering the quality, reliability and reputation of the compressor providers. What would the cost be to your business from lost productivity due to downtime or product spoilage and wasted resources due to poor air quality? Such costs could quickly obliterate the savings realised during the equipment purchase.