In short
Start with a flow meter on the main line, kWh measurement on the compressor and a pressure measurement at the far end. Then add meters to the branches. Consumption outside production hours shows leaks, and kWh/m³ shows efficiency.
Why measure?
Calculated and actual consumption rarely match: leaks, open drains and changing production load are not in the calculation. Measurement gives the starting point for improvement and the proof of the gain. At the design stage you can use our air consumption calculator to estimate consumption.
What is measured?
A low-cost, step-by-step measurement plan is usually enough:
- Flow: first the main line, then production area branches and large consumers.
- Pressure: compressor outlet and the inlet of the farthest consumer; the difference is the pressure drop.
- Electricity: compressor kWh; combined with flow it gives specific energy (kWh/m³).
- Temperature and dew point: for air quality and dryer performance.
Meter selection and installation
The most common method in compressed air is the thermal mass flow meter; it measures small flows well and needs no pressure/temperature correction. When selecting, consider pipe diameter, flow range, operating pressure and straight-pipe distances. In installation, flow direction, sensor position inside the pipe and dry air affect accuracy. You can find suitable sensors and measurement card solutions among our products.
What can be read from the data?
The constant consumption measured while production is stopped is your leakage. Comparing consumption per shift with production output gives air per unit of product. A logging system that alerts when a threshold is exceeded, together with remote access to the data, lets you catch deviations within the day.
Frequently asked questions
Where should I start measuring?
At the main line leaving the compressor room. Even a single flow meter gives a first picture of consumption and leak rate.
Thermal mass flow meter or another type?
For compressed air a thermal mass flow meter is mostly preferred. For large lines and high flows other methods may come up; choose according to your pipe diameter and flow range.
How do I make the measurement data permanent?
Connect meter outputs to a data logger or PLC and report daily/monthly. We can set up this structure with you through our energy monitoring service.
Figures given are typical values; the real saving in your plant is determined by measurement.
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Tell us what you need to measure — pressure, leaks or consumption — and our technical team will get back to you.