Optimizing System Output with Master Controllers

Simply put, master controllers allow for the consolidation of data from various compressed air systems in an industrial plant. This data, along with load variation analysis, can be hugely helpful in system-wide decision-making processes.

For instance, using this data, it’s possible to run compressed air systems to satisfy real-time compressed air requirements. Since these requirements can change daily, or even from one shift to the next, this approach can allow for significant energy savings. Consolidating all compressed air units to use a single master controller platform also ensures that no unit is running when it doesn’t need to be.

Master controllers allow compressed air demands to be met throughout all plant operations using the most effective combination of compressed air units. Plus, the real-time reporting can help in determining the optimal maintenance schedule for the units while allowing operators to easily assess equipment condition and plan for scheduled maintenance operations — before a system failure occurs. Since master controllers collect so much data, operators are able to thoroughly analyze output and ensure the smoothest, most efficient operations possible.

In this way, air compression controls can also help eliminate the costs associated with unplanned downtime. Although master controllers require investment upfront, the optimization of compressed air units can allow for significant cost savings over time.