Ecosave is an energy-saving solution for air compressors, designed specifically for factories operating 2–10 air compressors. Using real-time flow measurement and intelligent control, Ecosave reduces power consumption by 25–40%, keeps pressure stable and optimizes the entire compressed air system, with no need to replace your machines.
5 reasons why factories need an energy-saving solution for air compressors
Air compressors account for 30–70% of total electricity consumption in many manufacturing factories. However, most compressed air systems today share the same problems:
- Air compressors run continuously even as air demand changes → serious energy waste
- No precise control system → fans, dryers and water pumps are not switched off at the right time
- No data for optimizing energy use or reporting to management
- Operating costs keep rising, but there is no clear starting point for savings
→ This is why companies need a dedicated energy-saving solution for air compressors that is data-driven and adjusts automatically to the actual load.
Ecosave: an energy-saving solution for air compressors based on real-time flow measurement
Ecosave is a central control system for air compressors. It uses a flow meter to determine air demand at any given moment, and then automatically:
- Adjusts the number of air compressors in operation
- Reduces overcapacity operation
- Keeps pressure stable within the target range
- Optimizes the power consumption of auxiliary equipment
✔ Save 25–40% of power consumption
✔ No need to replace existing air compressors
✔ Optimize the entire compressed air system at all times
Common problems that drive up electricity costs in factories
- Air compressors run continuously even as air demand changes → wasted electricity
- The system is hard to control precisely → auxiliary equipment such as fans and dryers is hard to switch off
- No concrete data to justify or report on energy optimization
- Operating costs rise, but there is no clear starting point for savings
How Ecosave works – an energy-saving solution for air compressors
1. Measuring actual compressed air flow
The system continuously records:
- Air inflow and outflow
- Pressure over time
- Load fluctuations in each production shift
→ This is the foundation for accurate energy optimization.
2. Automatically controlling the number of air compressors
When air demand drops, Ecosave stops unnecessary machines. When demand rises, the system automatically starts backup machines to maintain pressure.
3. Fast response to changing loads
Ecosave can make adjustments in short cycles of just a few minutes, which operators cannot do manually.
4. Data storage and energy-saving reports
The system stores:
- Flow
- Pressure
- Machine running hours
- Fault history
- Energy savings by day/week/month
→ Supports production management and energy reporting.
5. Optimizing auxiliary equipment
Beyond the air compressors, Ecosave also optimizes:
- Cooling fans
- Dryers
- Cooling water pumps
- Cooling water valves
- Inverter control
→ Comprehensive energy savings for the entire system.
Illustration: Ecosave, an energy-saving device for air compressors
Illustration: air compressor energy-saving results with Ecosave
Ecosave compared with conventional air compressor control methods
Benefits of deploying Ecosave, an energy-saving solution for air compressors
⭐ 1. Save 25–40% on electricity
Based on actual operation and measured data.
⭐ 2. No need to replace air compressors
Ecosave is compatible with all brands: Hitachi, Kobelco, Atlas, Copco, Kaeser, Compkorea, Mitsui, SeikiIngersoll Rand.....
⭐ 3. Lower maintenance costs
Fewer running hours → longer service life → fewer breakdowns.
⭐ 4. Stable air supply and uninterrupted production
Includes a backup redundancy mode.
⭐ 5. Smart management
Data is displayed on a dashboard → easy to monitor and evaluate performance.
Illustration: core benefits of Ecosave, an energy-saving device for air compressors
Ecosave deployment process for air compressor energy saving
Step 1: Preliminary survey
Step 2: On-site measurement survey (2 days, free of charge, no installation work). Air flow measurement equipment is installed to accurately assess the savings potential.
Step 3: Performance simulation and investment cost calculation
Step 4: Discussion with the customer and confirmation of the proposal
Step 5: Deployment decision
Step 6: Manufacturing (1.5 months) - Installation (1 day) - Trial run (1 day)
Step 7: Reporting and operator training
Step 8: Customer feedback on results
Case Study - Results proven in real-world pilot projects
Overview of energy savings from 3 pilot projects
Ecosave has successfully completed 3 pilot projects, including 2 in-house trials in Japan and 1 on-site survey in Vietnam, with impressive results:
- Energy savings rate: from 23% to over 40%.
- Annual energy savings: from 32 MWh/year to 387 MWh/year.
- Payback period: fast, from as little as 1.4 years.
- CO₂ emission reduction: a significant contribution to corporate sustainability goals.
Pilot project results in detail
Project 1 (Pilot in Japan)
- Deployment date: October 2022.
- Number of air compressors: 4 units (3 x 37kW, 1 x 22kW).
- Energy savings rate: 44%.
- Annual energy savings: 139.0 MWh/year.
- Annual cost savings: 2.5 million yen/year.
- CO₂ emission reduction: approx. 67.4 tons/year (factor 0.485) or 91.5 tons/year (factor 0.6592)
- Payback period: 1.4 years.
Project 2 (Pilot in Japan)
- Deployment date: August 2022.
- Number of air compressors: 2 units (2 x 11kW).
- Energy savings rate: 46%.
- Expected annual energy savings: 32.0 MWh/year.
- Annual cost savings: 570,000 yen/year (factor 0.485).
- CO₂ emission reduction: approx. 15.5 tons/year (factor 0.485) or 21.1 tons/year (factor 0.6592).
- Payback period: 2.6 years.
FAQ – Frequently asked questions about energy-saving solutions for air compressors
1. Is Ecosave suitable for older air compressors?
Yes. Ecosave controls at the system level, so there is no need to replace machines.
2. Are 25–40% savings real?
Yes. These figures are confirmed by real-world trials in Japan and Vietnam.
3. How long is the payback period?
Typically 1.4 – 2.6 years, depending on the load and the existing system.
4. Does production have to stop to install Ecosave?
No. Installation takes only 1 day and does not affect the production line.
5. Why do air compressors consume the most electricity in a factory?
Because they typically run at excess capacity or are controlled by pressure rather than by actual flow.
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