Energy-saving solutions for air compressors reduce electricity consumption by

25-40%.

In the context of rising energy costs, optimizing air compressor systems – the most energy-intensive machines in a factory – has become a top priority. However, most businesses currently operate air compressors based on pressure, leading to tremendous energy waste when the machines run idle or discharge excess air.

Ecosave delivers a breakthrough: a centralized control solution based on actual flow rates, helping to reduce electricity bills by 25% - 40% immediately.

Most central controllers currently on the market use pressure information to operate:

• Difficulty in deciding to shut down the machine : When usage is low, the pressure increases, but the system has a pressure relief valve or the machine switches to idle mode. The pressure will not exceed the specified limit, causing the control panel to hesitate to order the machine to shut down for fear of a sudden pressure drop.

• Consequence: The control panel cannot identify when it is "safe enough" to shut down the machinery. If it is shut down by mistake while at full load, the sudden pressure drop will cause the entire production line to shut down.

• The reality is: The machines are still running, electricity is still being consumed, but it's not being used for production.

Ecosave solves this problem by adding a "flow control loop". The system accurately captures the current traffic flow and determines how many machines are sufficient, thereby turning machines on/off appropriately with extremely fast response times.

Ecosave completely changed the game by adding a flow control loop. Instead of guessing based on pressure, the system knows exactly how many m³/minute the plant needs.

2.1 Operating Principles of Ecosave

Ecosave is not just an ordinary electrical panel; it's the brain that analyzes real-world data from flow meters.

• During the production shift (increased flow rate): The flow meter sends a signal to the central control panel. When the set threshold is exceeded, Ecosave calculates and activates the second, third... air compressor within seconds to meet production needs immediately.

• During lunch breaks or shift changes (Traffic decreases): The system detects that traffic drops below the safe threshold. The control panel will accurately calculate the number of machines needed (e.g., only 1 machine instead of 2) and send a stop signal to the redundant machines.

Result: The air compressor is completely shut off when not needed, eliminating the wasteful idle running of electricity.

2.2 Operating Mechanism

Measure actual compressed air flow rate: The system continuously records:

• Real-time airflow rate

• Load fluctuations vary across production shifts and operating hours.

→ This is the core data platform for precisely scheduling compressors, optimizing power consumption, and reducing unnecessary usage.

Automatic control of the number of air compressors:

• When gas demand decreases, Ecosave automatically shuts down unnecessary compressors, preventing over-operation.

• When demand increases, the system automatically activates the backup machine, ensuring stable and continuous pressure for production.

→ Helps optimize power consumption, reduce equipment wear and tear, and improve overall system stability.

Respond quickly to changing loads.

• Ecosave can monitor and adjust to load fluctuations in just minutes, ensuring the air system always operates closely to actual demand.

• Rapid response helps avoid overrunning, voltage drops, or slow on/off cycles that waste electricity – issues that manual operation cannot address in a timely manner.

• Record real-time data on flow rate, pressure, power consumption, and operating time of each compressor.

• Automatically generates reports by shift, day, week, and month, clearly showing electricity savings, operational efficiency, and energy consumption trends.

→ Ecosave helps the system react instantly to load fluctuations and provides transparent data, creating a foundation for continuous, verifiable, and measurable energy optimization.

Storage system:

• Flow rate

• Pressure

• Number of machine operating hours

• Error history

• Electricity savings per day/week/month

→ Support in production management and energy reporting.

2.3 Benefits of Implementation 

• Saves 25-40% on electricity: Proven through real-world case studies.

• Save on maintenance and repair costs.

• No production interruption: Rapid installation of surveying equipment, without interfering with pipeline infrastructure.

• Increase equipment lifespan: Reduce the number of hours of wasted operation for air compressors.

2.4 Conditions for the most effective Ecosave implementation

For optimal performance and the quickest return on investment, the factory's compressed air system needs to meet the following requirements:

• Quantity: Two or more air compressors are required.

• Configuration: The system should include at least one machine using an inverter (INV) to regulate the pressure range more smoothly.

• Power: Suitable for all power ranges, but offers the most significant economic benefits with machines of 37kW and above.

• Scalability : Ecosave employs a modular control architecture, allowing for flexible expansion based on the number of air compressors. For systems with more than 6 compressors, the control software is custom-programmed to synchronize the entire unit, ensuring precise load management and long-term stable operation.

2.5 Survey and Measurement Process: Commitment in Numbers

We understand that every energy-saving solution requires real-world data. Therefore, Ecosave implements a "See it - Hear it - Get real data" process:

1. Preliminary survey: Assessment of the current compressor system configuration.

2. Two-day trial (Free): Using Keyence ultrasonic flowmeters mounted outside the pipeline. This method requires no pipe cutting or construction, ensuring normal plant operation.

3. Simulation & Reporting: Based on 2 days of data, we generate a simulation report showing the amount of electricity that could be saved by installing an Ecosave cabinet.

4. Investment decision: After receiving a detailed savings report, your company will then proceed to discuss the official implementation of the installation.

Overview of electricity saving effectiveness from 3 pilot projects

Ecosave has successfully completed three pilot projects, including two internal trials in Japan and one field survey in Vietnam, yielding impressive results:

• Energy saving rate: Achieved from 23% to over 40%.

• Annual energy savings: From 32 MWh/year to 387 MWh/year.

• Reducing CO₂ emissions: A significant contribution to the company's sustainability goals.

Project 1 (Tested in Japan) 

• Implementation time: October 2022.

• Number of air compressors: 4 (3 x 37kW, 1 x 22kW).

• Energy saving rate: 44%.

• Annual energy savings: 139.0 MWh/year.

• CO₂ emission reduction: Approximately 67.4 tons/year (factor 0.485) or 91.5 tons/year (factor 0.6592).

Project 2 (Testing in Japan) 

• Implementation time: August 2022.

• Number of air compressors: 2 (2 x 11kW).

• Energy saving rate: 46%.

• Expected annual energy savings: 32.0 MWh/year.

• CO₂ emission reduction: Approximately 15.5 tons/year (factor 0.485) or 21.1 tons/year (factor 0.6592).

 CONTACT US 

SAO MAI SOLUTIONS GROUP JOINT STOCK COMPANY

Address: 25 Nguyen Quoc Tri Street, Yen Hoa Ward, Hanoi

📞 Hotline EN-VN: 090 8184 188 /0869191169

Email: info@saomaisoft.com

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