Fixing leaks in the compressed air system cuts costs

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Energy Carbon
Manufacture of rubber and plastic products
Investment cost:
Medium cost
Payback time:
The only cost is the time spent by employees to check the installations. Payback time is immediate if leaks are found.
Medium cost
Co2 emission reduction:
63 tonnes per year
Size of company:
Medium (less than 250)
Advancement in applying resource efficiency measures:
Beginner Intermediate Advanced

Air of confidence in efficiency monitoring

  • Company decides to implement routine checks of compressed air system
  • Savings in both energy and emissions prove the value of energy performance monitoring 

The German company AKRO-PLASTIC GmbH produces plastic compounds, which are processed into technical components for the automotive industry by other companies. The company works with polymers in an application-orientated business; mainly using a twin-screw plastic extruder but also strand and underwater pelletising.

AKRO-PLASTIC has a huge compressed air system for working with polymers. Leaks in the high-flow compressed air system are costly and time-consuming. The energy required to compensate for pressure losses in the event of leaks is very high.

As part of an efficiency analysis, the company sent out two workers to systematically check for leakages and flag them for immediate repair.

Key results

Within three weeks, the inspectors found leaks which would cost the company around € 11 000 per year. Fixing the leaks promptly also prevented around 62 tonnes of CO2 emissions per year. Inspired by the outcome, AKRO-PLASTIC plans to continue routine checks of its compressed air system.

Effizienznetz Rheinland-Pfalz, Ressourceneffizienz in der Kunststoffproduktion,…

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