Turn compressor data into clear annual savings estimates. Model upgrades, rebates, and demand charges easily. See payback, NPV, and cashflows before investing wisely now.
Use these sample values to test the calculator and validate your workflow.
| Rated kW | Load % | Motor % | Improve % | Hours | Rate | Demand | Coincident | Maint | Cost | Rebate |
|---|---|---|---|---|---|---|---|---|---|---|
| 75 | 70 | 93 | 10 | 5000 | 0.14 | 12 | 0.70 | 800 | 12000 | 1500 |
| 55 | 60 | 92 | 8 | 4200 | 0.11 | 9 | 0.60 | 600 | 9000 | 1000 |
Tip: If demand billing is not applicable, set demand charge to 0.
This model is an estimating tool. Actual savings depend on control strategy, system pressure, leaks, storage, distribution losses, and operating profiles.
For better accuracy, use measured kW data from a power meter and validate savings with post-implementation trending.
Compressed air ranks among the costliest utilities in a plant. This calculator converts motor input power into annual kWh using operating hours. For example, a 75 kW compressor at 70% load and 93% motor efficiency draws about 56.45 kW. Over 5,000 hours, that is roughly 282,000 kWh. At $0.14 per kWh, energy cost is about $39,500 per year, so efficiency gains can matter.
Many tariffs add a monthly demand fee based on peak kW. The model estimates demand savings as kW reduction multiplied by a coincident factor and the demand charge, then annualizes it over 12 months. If kW drops by 5.65 and the coincident factor is 0.70, a $12 per kW‑month charge yields about $569 per year. Sites with higher demand rates or better coincidence can see larger savings.
Net investment equals project cost minus rebates. Simple payback divides net investment by total annual savings, combining energy, demand, and maintenance. NPV discounts each year’s savings at your chosen rate, reflecting time value of money. IRR is the rate that makes NPV equal zero. With $10,500 net cost and $5,300 annual savings, payback is near 2.0 years and IRR can exceed typical hurdle rates.
Savings are proportional to hours and to the verified kW reduction. When possible, use logged power data before and after improvements, especially for variable‑speed controls and pressure optimization. A 1% error in assumed load can shift savings noticeably across thousands of hours. Consider testing different improvement percentages and electricity rates to understand upside and downside cases.
Focus first on low‑cost measures: leak repair, pressure setpoint reduction, and sequencing multiple compressors. Then evaluate controls, storage, and high‑efficiency motors. Capture rebates early, and confirm baseline conditions during production periods. After commissioning, trend kW and system pressure for several weeks to confirm persistence. Document assumptions so finance can reconcile results with utility bills.
It is the expected percentage reduction in input kW from measures such as leak repair, pressure optimization, better controls, or upgraded equipment, assuming the same delivered air service and operating schedule.
Use 0.5 to 0.8 if the compressor usually runs during peak demand windows. If peaks occur when the compressor is off, use a lower value. Metered load profiles give the best estimate.
The calculator converts delivered shaft power to electrical input. A lower motor efficiency increases baseline kW and increases potential savings for the same improvement percentage, especially for heavily loaded machines.
Not directly. Those effects are captured indirectly through the improvement percentage and load assumptions. For leak programs, estimate kW reduction from measured flow and compressor performance or from pre/post power logging.
Year 0 is the net investment, and each following year uses the same annual savings. NPV discounts those cashflows at your discount rate. IRR is the discount rate that makes NPV equal zero.
Yes. After a calculation, use the CSV download for a field-by-field record. The PDF button captures the results panel, including KPIs and the chart, for sharing with finance or management.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.