Software innovation cuts maintenance costs and boosts compressed air efficiency

The annual maintenance costs of a compressed air system can total 10 per cent or more of the initial investment, depending on the size of the installation and the type of compressors in use.

Energy use represents an even more significant expense, accounting for between 70 and 80 per cent of the system’s overall cost. Inefficiencies in non-optimised equipment can lead to energy losses of up to 30 per cent, putting further pressure on operating budgets.

To help manufacturers address these challenges, CompAir has launched its new Compressed Air Management Solution powered by Ecoplant, a cloud-based system designed to improve operational reliability while reducing cost and emissions. The platform forms a central part of CompAir’s enhanced ASSURE service programmes, which now offer more proactive maintenance support, faster service response and comprehensive lifecycle assistance.

At the heart of the new solution is Ecoplant Monitor, a software package that continuously analyses compressor and dryer performance and alerts CompAir technicians as soon as any irregularities occur. This allows the service team to intervene before issues escalate, helping customers minimise downtime and better manage the long-term costs of their equipment.

The system provides full visibility of lifetime, energy and maintenance expenditure and requires no installation work for users with compressors already fitted with CompAir’s iConn connected platform.

Data from iConn feeds directly into Ecoplant Monitor, enabling customers to access a unified, intuitive interface that presents real-time operating information and historical performance trends.

The platform’s analytical tools provide early warnings, guidance on corrective actions and insights into potential energy savings. Its AI-supported diagnostics help speed up troubleshooting and repairs, particularly when used alongside CompAir’s ASSURE service teams. The system also measures energy consumption and carbon footprint, helping businesses track progress against sustainability targets.

CompAir’s ASSURE service agreements — AssurePLAN, AssureCOMPLETE and AssurePLAN+ — have been developed to suit a range of plant requirements, offering different levels of support depending on operational needs. When combined with the real-time intelligence generated by Ecoplant Monitor, these plans help customers maintain system health, reduce risk and lower total cost of ownership while improving environmental performance.

CompAir has also expanded its digital offering with Ecoplant Optimize, which builds on the monitoring capabilities of Ecoplant Monitor by introducing active, automated optimisation. Using dynamic control algorithms, the software manages all compressors in a system, adjusting setpoints and determining the most efficient combination of units at any given moment. This enables measurable improvements in energy efficiency, leak detection, auditing accuracy and real-time verification of savings.

Andrea Milla, business development manager at Ecoplant, said the progression from monitoring to optimisation marks a significant step in helping customers improve reliability and cut CO₂ emissions. “Monitor is the starting point, Optimise is the next step,” he explained. “By moving from monitoring to optimisation, customers can realise measurable improvements in energy efficiency, operational reliability and CO₂ reduction.”