Blog - Air Compressors

10 Steps to Savings – Working with Air  Compressors

 

Date: July 28, 2025
Author: Evan Lobdell

Air compression is essential across a wide range of industries, but it can also be one of the most expensive utilities in any facility. According to the U.S. Department of Energy, compressed air often accounts for a significant portion of energy costs. The good news? With the right strategies, you can maximize the efficiency, reliability, and longevity of your Atmos compressor system—and save on energy bills.

In this guide, we’ll cover 10 practical steps you can take today to optimize your Atmos compressor and boost overall system performance.

1. Understand Your Facility’s Demand

Every facility is unique. Factors like altitude, temperature, and operating shifts can impact compressor efficiency. Demand also changes throughout the day depending on production levels.

An air audit from an authorized Atmos distributor can help you measure your facility’s compressed air demand and ensure the system you’re using is the best fit. In many cases, running two or more compressors—rather than one oversized unit—may be the most efficient choice.

2. Assess Your Compressor Room

Where you install your Atmos compressor directly affects its performance. Compressors work best in well-ventilated areas with controlled room temperatures. Dust, dirt, and high heat can lead to inefficiency and costly repairs.

By selecting the right room, you’ll reduce downtime and keep your Atmos compressor running smoothly for years to come.

3. Match Compressors to Specific Tasks

Compressed air is one of the largest energy consumers in most industrial facilities. Using the wrong compressor for the wrong task wastes money:

  • Too large: You’re overpaying for energy and capacity you don’t need.
  • Too small: You won’t meet production demands.

Optimize your system by assigning the right Atmos compressor to the right job to maintain energy balance.

4. Monitor Load Cycles

Frequent start-stop cycles increase energy consumption and wear on your compressor. If your Atmos compressor is cycling too often, adjusting the pressure set points can improve efficiency.

Remember: changing pressure affects system operation but does not increase or decrease airflow (cfm)—a common misconception.

5. Turn It Off When Not in Use

Just like electronics at home that consume “phantom power” when plugged in, compressors can waste energy when left running idle. If your Atmos compressor isn’t needed—overnight, weekends, or during production lulls—turn it off completely to reduce unnecessary energy usage.

6. Replace Filters Regularly

Air filters keep dust and debris from entering your Atmos compressor. A clogged filter forces the machine to work harder, driving up energy costs.

We recommend replacing inlet air filters every quarter for maximum efficiency.

7. Perform Oil Sampling and Fluid Changes

Lubrication quality is key to compressor health. Regular oil sampling can reveal potential issues before they cause downtime. Generally, fluids should be replaced annually, though dusty or dirty environments may require more frequent changes.

Always consult your Atmos compressor user manual for the correct service intervals.

8. Watch for Air Leaks

Air leaks are one of the biggest hidden costs in compressed air systems. Studies show that up to 50% of compressed air is wasted, with leaks accounting for about a third of that loss.

Leaks force your Atmos compressor to work harder, driving up energy costs. For example:

  • A 200 cfm leak can cost $27,139/year.
  • A 300 cfm leak can cost $40,709/year.
  • A 400 cfm leak can cost $54,278/year.

Regular inspections help detect and repair leaks quickly.

9. Take Daily Walks Around Your Operation

Preventive maintenance starts with awareness. A quick daily walk-through to inspect your Atmos compressors can help you catch problems early. Look for:

  • Clogged filters or coolers
  • Damaged piping
  • Heat discoloration on parts

Much like a pilot’s pre-flight check, this habit helps ensure your system runs reliably and avoids costly emergency repairs.

10. Assess and Track Energy Savings

Once you’ve optimized your Atmos compressor system, measure your results. Tools like Atmos AirSuite™ allow authorized distributors to provide a detailed analysis of your system and calculate real energy savings.

Tracking performance gives you the data you need to make smarter decisions and continue reducing costs over time.

 

 

 

 

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