Compressed-air optimisation

Q: How much air leaks?

Unmanaged systems: 20–40% of compressor output. Weekend pressure-decay tests quantify it in one log.

Q: What's the cheapest fix?

Leak repair + setpoint reduction — often six-figure savings with hand tools and discipline.

Q: Can I recover compressor heat?

Yes: 70%+ of electrical input is recoverable as hot water/air — frequently the largest single heat-recovery stream in light industry.

Compressed air is the most expensive utility per delivered joule: ~90% of input power becomes heat, and leak rates of 20–40% are routine without a programme.

Size it for your plant →Carbon bill calculator

The numbers

Cost, effect, payback

Metric	Value	Note
Abatement cost	≈€-10–15/t CO2
Addresses	20–40% of CA energy	of relevant emissions
Typical payback	<2 yr
Carbon value at full price	€77.4/t avoided	EUA 11 Jun 2026

How it works

Mechanism & sizing

Sequence: leak survey (ultrasonic) → pressure reduction (each 1 bar ≈ 7% energy) → eliminate inappropriate uses → heat recovery from compressors (70%+ of input recoverable as 70–90 °C water). The last one is a heat-supply measure hiding in the electrical room.

Inzonex removable modular insulation on industrial equipment

Cut the tonnes at the source

Hot industrial equipment? Cut the heat loss.

Boilers, kilns, heat exchangers, valves and steam lines lose energy continuously. Inzonex makes patented (UK GB2508992.1) removable modular insulation — snap-fastened covers engineered per temperature tier, not generic off-the-shelf jackets:

Up to 90% less heat loss from insulated surfaces
Surface temperature ≤45 °C — touch-safe for workers (EN ISO 13732-1)
6× faster maintenance access than fixed cut-and-weld lagging — unclips and refits in minutes, no destruction
Inspectable — comes off to check for corrosion under insulation, then refits like-new (generic jackets often don't survive removal)
Typical payback under 2 years (some 9–11 months)

See Inzonex process-equipment insulation →Run the savings study

FAQ