COMPRESSORS PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 30 A compressed air system monitoring and control network Automatic learning and management based on an article by Andrea Milia, Business Development Manager at Ecoplant Ecoplant is a stand-alone and plug-and-play solution that can be connected to all compressed air technologies. It offers a distinctive dynamic control system for managing any compressor room by analysing multiple variables. This data feeds into an algorithm that enables fast decision-making. The proper management of compressed air remains a significant challenge for industrial companies operating in markets characterised by high energy cost volatility and a need to minimise unpredictable events, such as equipment failures or system outages. Notably, the electricity required to power compressors can account for up to 30% of a facility’s total energy consumption. In addition to energy costs, expenses related to routine and extraordinary maintenance, as well as the risks posed by malfunctions and system interruptions, including potential plant downtime, represent a substantial portion of a company’s operating expenses. To address the demand for optimal compressed air management, Compair has developed Ecoplant, a monitoring and control system for the compressed air system based on Machine Learning models. Ecoplant is a machine agnostic solution: it can work with any brand and type of compressor. It features a distinctive “dynamic control” capability, which manages compressor rooms through the real-time analysis of multiple variables. These variables continuously feed into an algorithm that enables fast, reliable decisionmaking. Operation To better understand how Ecoplant works, it is helpful to introduce its physical components. Sensors monitor key variables required by the algorithm, such as pressure, flow, dew point, and others. These readings are then transmitted to the dynamic controller. The cloud-based algorithm receives, analyses, and processes the data from the plant’s sensors with the aim of optimising system efficiency. After a baseline period, Dynamic Control is activated. At this stage, artificial intelligence takes over system management to ensure the lowest possible specific energy consumption. This optimisation is made possible through the continuous adjustment of set-points and the selection of the optimal operating configuration for the compressors, based on real-time air demand and conditions. Energy savings are even greater in systems with centralised compressor rooms, equipped with variable speed or centrifugal compressors, and where the air demand fluctuates greatly over time. Compair aims to combine a strong commitment to customer support with a forward-thinking approach, seeking to enhance the value and performance of its equipment through flexible, future-ready solutions. Beyond energy efficiency The benefits of Ecoplant go beyond electricity savings, says Compair. Users have continuous access to a user-friendly monitoring platform that provides real-time insights into the performance of the entire compressed air system, including individual variables, compressors, and dryers of interest. The platform also allows for unlimited access to and download of plant data and data from all connected components. Through machine learning, Ecoplant not only issues timely warnings and alerts but also supports predictive maintenance. This helps reduce both routine and unplanned maintenance COMPRESSORS Display of saved energy
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