SteddyAir / Plant efficiency
Energy Savings
Compressed air is usually the most expensive utility in a plant. We find where it is being wasted — and get it back.
The waste is measurable
CFM in. kW out. Dollars over the year.
CFM
flow measured at the system
PSI
pressure the plant actually needs
kW
power used to make the air
$
annual cost of the loss
Start with the number
Compressed air typically takes a large share of a facility’s electricity bill, and most of the loss is invisible — leaks, over-pressure, oversized equipment and controls that never got tuned. SteddyAir measures it, quantifies it in dollars, and fixes it.
01 / Optimize
Energy Savings & System Optimization
We tune the system around real demand, not the worst day of the year. That means less compressor work for every unit of air your plant uses.
- Right-size compressors to real demand instead of peak-day demand
- Reduce header pressure to the lowest pressure the plant actually needs — 1 PSI is roughly 0.5% of compressor energy
- Eliminate artificial demand, storage and sequencing issues
- Verify results with measured data, not estimates
What you get
Lower kWh per unit of air produced, with the numbers to prove it.
02 / Measure
Compressed Air Audits
A calibrated snapshot of what the compressors make, what the system uses and where the gap costs you money.
- Baseline measurement of flow, pressure and power across the system
- Load/unload and pump-up testing with calibrated instruments
- Use of CAGI performance data to verify compressor output and specific power
- A written report ranked by savings, cost and payback
- Actions you can implement in-house versus work we do for you
What you get
A prioritised, costed plan — not a binder of graphs.
03 / Find the loss
Leak Detection
Leaks are a production problem and an energy problem. We find them while the plant is running, then verify the repair.
- Ultrasonic leak survey during production and during shutdown
- Every leak tagged, located and photographed
- Each leak quantified in CFM, kW and annual dollars
- Repair list sorted by size of loss, plus verification that repairs held
What you get
Most plants find leaks worth 10–30% of compressor output — money currently going to the atmosphere.
04 / Integrate
Controls & Integration
The controls should follow demand without making the operators babysit the system. We connect the pieces and make the result visible.
- Master controllers sequencing multiple compressors to run only what is needed
- VSD and fixed-speed coordination, trimming and rotation
- Pressure/flow control and storage strategy to stabilise the header
- Monitoring and reporting so the savings stay put with Airleader systems
- Integration with existing plant controls and dryers
SteddyAir integrates Airleader, a German compressed air management system, to give plants continuous, measured visibility of their compressed air supply and demand — rather than a one-off audit snapshot.
25+ years
developing compressor master control and monitoring systems
10,000+ installations
the most widely installed OEM-independent compressor master control
ISO 50001
energy management
ISO 8573-2010
compressed air quality
Sponsor
of the Compressed Air Challenge
Winner
Energy Efficiency Award Challenge 2016
What the system measures and does
- Compressor master control — sequencing multiple compressors, VSD and fixed-speed coordination, trimming and rotation, tight pressure control
- Supply-side monitoring — flow, pressure, power and compressor loading, live and historic
- Demand-side monitoring — down to individual processes, so losses can be located, not just detected
- Air quality — dew point, particles and residual oil content (ISO 8573-2010), which matters in food, pharma and packaging
- Permanent and temporary data logging, system audits, evaluation and system simulation
- Automatic energy reporting with alerts, plus heat-recovery and no-loss drain monitoring
- Permanent measurement so savings are verified in kWh rather than estimated
Methodology: savings from a measure are verified against measured kWh, so each measure can be allocated its own saving — leak repair, dryer replacement, master control and monitoring — instead of a single pre/post audit estimate that blurs five measures together.
SteddyAir can arrange a webinar or a walkthrough of the Airleader master controller for anyone evaluating it. Ask us for a walkthrough
What you get
The right compressor at the right time, automatically.
This demo shows the Airleader web-based monitoring and control dashboard SteddyAir installs — explore live pressure, flow, power and compressor sequencing data without installing anything.
05 / Recover the cost
Incentives & Rebates
The work often pays for itself faster with a utility incentive. SteddyAir handles the technical side of the application so the baseline, savings case and equipment documentation line up.
Estimate your incentiveThe Ontario Save on Energy Retrofit Program — Custom Stream, delivered by the IESO, supports non-lighting measures including compressed air. The incentive is the greater of $1,800 per kW of peak demand savings or $0.20 per kWh of energy savings, based on actual operating conditions, up to 50% of eligible project costs.
246,164
kWh saved
29.75
kW saved
$36,101
incentive
Programme case study
Two 100 HP fixed-speed compressors were replaced with one 75 HP variable-speed compressor plus one 100 HP fixed-speed compressor. The $72,201 project received a $36,101 incentive — 50% of project cost.
SteddyAir’s role
Measurement, baseline and M&V support, compressor and system documentation, and the programme worksheet case.
When Custom is not the fit
The Prescriptive stream has fixed per-unit amounts for common measures such as VSD compressors, primary air receiver tanks, zero-loss drains and cycling dryers when a project fits those criteria.
Make the loss visible
Find out what your compressed air is costing you
Book a no-obligation air audit with same-day scheduling. Surveys are usually done during normal production, so your plant is unlikely to be down for it.