Compressed air is one of the most energy-intensive utilities in food production. During day-to-day operation, however, it is often unclear exactly where unnecessary energy consumption occurs.
The challenge: Lack of transparency regarding leaks and load distribution
A food manufacturer was struggling with steadily rising costs for its compressed air supply. Because neither leaks nor inefficient load distributions were visible, the causes could only be suspected, not proven. This is where in.hub GmbH provided support with its expertise in the acquisition and analysis of industrial energy data.
The solution: Continuous compressed air monitoring with local data analysis
Using the in.hub HUB-EN200 in combination with the SMC Air Management System (AMS), flow rate, pressure, and compressor load were continuously monitored. in.hub enabled local analysis of the measurement data, making hidden leaks and unused compressed air capacities visible. After these issues were resolved, the compressors could be operated more efficiently and load cycles optimized.
The result: Reduced energy demand and measurable cost savings
- 17% reduction in energy demand for compressed air generation
- 18.6 MWh / €3,720 savings per year
- 6.5 tonnes less CO₂ emissions annually
The improved transparency also enables preventive maintenance and long-term optimization of the compressed air network.
Profitability
Total investment: €4,300 (€1,300 for HUB-EN200 + HUB-GM200 + accessories, approx. €3,000 for AMS) → Payback period: 14 months.
Facts at a glance
| Industry | Food production |
| Use case | Compressed air monitoring |
| Solution | HUB-EN200 + SMC Air Management System |
| Solution provider | in.hub GmbH |
| Result | −17% energy, €3,720 savings p.a. |
| Amortization period | 14 months |
| Investment | €4,300 |
| CO₂ reduction | 6.5 t per year |
