Optimization of Energy Consumption in Compressed Air Systems with Green Transformation Strategies in Wheel Manufacturing

Wheel manufacturing is recognized as a highly energy-intensive sector with considerable potential for improving air efficiency. In this facility, a 160 kW inverter compressor is currently operated at 60% capacity, even when air demand is low, leading to unnecessary energy consumption. To enhance compressed air system efficiency, two inverter-equipped NEMA Class 1 compressors are being integrated and are managed through a centralized SCADA system. By reducing air leaks and optimizing motor performance with Variable Speed Drives (VSD), energy cost reductions of $\mathbf{1 5 - 4 0 \%}$ are anticipated. A comprehensive energy analysis has revealed a $\mathbf{3 6 . 8 5 \%}$ energy loss in these air distribution lines, primarily due to suboptimal compressor operation. Through real-time monitoring and control, significant reductions in these losses are expected, ensuring improved energy efficiency and supporting sustainable operations within these manufacturing processes.