Kaeser Compressors has performed more than 10,000 air system audits in the United States, and we have found that, on average, users operate at only 44% of total capacity. Despite a concerted effort by compressed air professionals to educate users about the negative impacts of oversizing on operations and the bottom line, gross oversizing remains common practice.
How does this happen? In many cases, users select compressors based on the compressor(s) that they already have, adjusted with some prognostication about expected business growth. Generally, little measurement and analysis goes into it. Also, most operators are inclined to up-size for peace of mind. They don’t want to hear complaints of equipment with low pressure alarms, nor do they want to re-revisit compressed air system design every few years as they grow. So, they purchase as big as their budget allows at the outset.
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