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Compressor

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A compressor compresses gas to generate compressed air, serving as a power source for various types of machinery, such as machine tools and other industrial equipment. It is an essential machinery in nearly all factories, playing a crucial role in production processes. Compressors consume a significant amount of electricity, accounting for about 25% of a factory’s total power usage. Therefore, adopting energy-efficient compressors is not only vital for reducing manufacturing costs but also for contributing to a decarbonized society.

Peripheral equipment

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We also offer a range of peripheral equipment designed to achieve greater energy savings. These include a control panel that optimizes the operation of multiple compressor units, an exhaust heat dryer that utilizes waste heat from oil-free compressors, and a hot water recovery unit that recovers thermal energy from compressors for heating boiler feedwater, among other products that further enhance efficiency and energy savings.

Energy Audit

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To enhance energy efficiency, it is essential to first understand the current situation. We offer a “Compressor Load Diagnosis,” which measures and analyzes compressor energy usage to propose energy-saving improvements, as well as an “Air Leak Diagnosis,” which identifies air leaks on the user side and calculates the annual cost of these losses. By providing these services, we deliver a one-stop solution for optimizing compressed air energy usage throughout the entire factory.

Energy saving case studies

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We provide solutions for customers facing challenges such as improving the energy efficiency of compressor equipment and centralizing the management of operating conditions. Our services include measuring and analyzing actual operating conditions, recommending and installing the most optimal equipment, and assessing the resulting effects. In addition to the standard energy-saving approach of adopting inverter compressors, we implement further innovations to help our customers achieve even greater energy savings.
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Analysis of compressor operations with simulations for energy savings

At KOBELCO, as compressor professionals, we conduct load diagnostics, data analysis, and propose energy-saving improvements, along with calculating energy-saving effects—regardless of the manufacturer or compression method. We support your investment decisions with data-driven insights.

Air leakage diagnosis

It is commonly said that 15-30% of compressed air is lost due to leaks. To save energy in compressed air systems, it is essential not only to optimize the compressor but also to address air leaks. However, detecting air leaks by sound or sight alone is extremely difficult. At KOBELCO, we provide a diagnostic service that visualizes air leaks using frequency detection at pipes, joints, hoses, and connections. Our reports clearly present annual cost losses and CO2 emissions, making it easy to understand the impact of air leaks.

Group Controller

A control panel that automatically selects and operates the optimal number of compressors based on changes in air consumption, achieving energy savings when using multiple compressors. When paired with an inverter compressor, its energy-saving performance is significantly enhanced.

Heat of Compression Dryer

The exhaust heat dryer utilizes compressed exhaust heat from an oil-free compressor to dry compressed air and regenerate the desiccant, operating with just 15W of power (for the ED160 model) for energy-efficient operation.

Heat recovery

The hot water recovery unit captures and effectively utilizes thermal energy that would otherwise be lost through cooling towers and other means. By recovering up to 92% of exhausted thermal energy, it enhances overall factory energy efficiency, reduces electricity and gas costs, and lowers CO₂ emissions. The recovered thermal energy can be repurposed for various applications, including heating boiler feedwater, powering heaters, showers, and thermal water pools.

Oil injected compressor

An oil-flooded (oil-injected) compressor injects oil into the screw rotor, forming an oil film that prevents air leakage while generating compressed air. KOBELCO offers a lineup of industry-leading oil-injected compressors, including the "KOBELION VS," an inverter-driven model for maximum energy savings; the "KOBELION AG," a premium fixed-speed model, and the "KOBELION SG," a standard model.

Oil-free compressor

Oil-free compressors produce compressed air entirely free of oil particles, making them indispensable in industries such as food processing, chemicals, and semiconductors, where contamination-free air is crucial. KOBELCO offers an industry-leading lineup of oil-free compressors, categorized by output levels and compression methods to ensure optimal energy efficiency. We can provide the ideal model to meet your specific application requirements.

Case 1: Energy-Saving Solution with Inverter Compressors

Previously, only constant-speed compressors were used. However, because the required compressed air volume fluctuated significantly depending on the number of operating units, inverter compressors were selected for their energy-saving potential based on real-time operating conditions. Line pressure control was implemented on the inverter compressors, enabling operation at optimal pressure settings near the usage points at all times, resulting in a pressure reduction of approximately 1.5 bar. Additionally, by utilizing the group control function, the entire system achieved around 13% energy savings (approximately 120,000 kWh annually).

Case 2: Energy Savings Using Heat of Compression dryer

Based on the analysis of actual operating data, inverter compressors were selected to optimize energy savings according to varying operating conditions. Additionally, a load control system was implemented to automatically shut down unnecessary machines during low factory loads, minimizing idle standby time. To maintain air quality while enhancing energy savings, heat of compression dryers were also introduced. By integrating these systems with the existing internal network, centralized management of operating conditions was achieved.
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