Compressed Air Tech Breakthroughs That Are Reshaping Manufacturing

During a discussion with Thiruamuthan, Assistant Editor at Industry Outlook, Bhavesh Karia, Executive President – ISAAME & SEA, Elgi Equipments Limited, discusses how compressed air systems are evolving from basic utilities into intelligent infrastructure that helps Indian manufacturers cut energy losses, protect uptime and meet sustainability expectations in a cost- and performance-driven industrial environment.

Bhavesh Karia is a global business transformation leader with 27+ years of experience across energy, infrastructure, EPC, international growth, P&L and leadership.

With compressed air accounting for a major share of industrial energy use in India, how are advanced compressor technologies helping manufacturers reduce operational inefficiencies at scale?

With compressed air often accounting for 10–30 percent of a plant’s electricity consumption, driving transformative efficiency gains is one of the quickest ways to cut energy costs at scale.  With said that, to give a clear picture by giving a reference of ELGi’s advanced compressor technologies are engineered to minimise these systemic losses while enhancing reliability and uptime.

Our patented Demand=Match system brings dynamic intelligence to fixed-speed compressors by smartly recirculating airflow so that delivery precisely follows real-time demand. By reducing unnecessary load and unload cycles, customers have recorded energy savings of up to 17 percent, along with significantly lower mechanical stress and longer equipment life.

These advancements integrate high efficiency airend design, optimised package architecture, and intelligent electronic controls to reduce wastage in real-world operating conditions. Manufacturers across textiles, automotive, and general engineering are already realising measurable gains: reduced operating costs, improved system stability, and higher uptime, all contributing meaningfully to their sustainability goals.

As predictive maintenance becomes essential for uptime in high-throughput factories, how are Indian manufacturers leveraging sensor-based compressed air monitoring to prevent unplanned production halts?

As factories run closer to full capacity, predictive maintenance has become critical to protecting uptime. Traditional reactive maintenance waits for a breakdown, while time-based preventive schedules often lead to over-servicing. Predictive approaches, powered by sensors, connectivity and analytics, allow maintenance to be planned exactly when the machine needs it, reducing both unexpected stoppages and unnecessary interventions.​

Manufacturers are increasingly using sensor-based compressed air monitoring to achieve this. Our latest compressors come pre-equipped with IoT connectivity, securely transmitting key parameters such as pressure, temperature, run hours, power consumption and alarms for continuous monitoring. This gives plant teams real-time visibility, data-driven insights and early warning of anomalies, empowering manufacturers to optimize operating costs and total cost of ownership.​

One such example is ELGi’s Air Alert system, which takes this capability a step further. It provides 24/7 remote monitoring, intelligent algorithms that predict commonly occurring failures, and proactive alerts for faults and upcoming service needs, delivered via easy-to-read dashboards and reports. Customers can schedule maintenance at convenient windows, ensure resilient, disruption-free operations and improve energy efficiency by acting on utilisation trends and leak indicators. In high-throughput industries such as textiles, automotive and general engineering, this approach to compressed air systems is already translating into higher uptime, lower maintenance costs and more stable, reliable operations.  This is not just about cost optimization and sustainability gains, it’s about shaping a future-ready, low-carbon manufacturing ecosystem. These digital capabilities position manufacturers at the forefront of Industry 4.0, enabling predictive insights and agile decision-making.

Also Read: How Smart Factories Driving Efficiency in Auto Manufacturing

Given that many Indian plants still run on overdesigned or outdated compressor systems, what’s driving the shift toward retrofitting with energy-optimized, smart air solutions?

Across India, many plants still operate oversized or legacy fixed-speed compressors that cycle heavily between load and unload, wasting energy and creating unstable pressure. Rising electricity costs, tighter efficiency norms, and the need to improve reliability without replacing entire compressor rooms are pushing manufacturers to retrofit their existing assets with energy-optimised, smart air solutions.

One of our key answers is the patented DEMAND=MATCH SYSTEM for fixed-speed compressors. Instead of running at constant output or needing an expensive VFD, this intelligent system smartly recirculates airflow inside the compressor so that delivery closely follows real-time plant demand. By keeping “demand matched to delivery”, it cuts unnecessary load and unload cycles and pressure overshoot, delivering measurable impact of up to about 17 percent lower energy consumption in typical operating profiles while improving reliability and extending equipment life.

Because DEMAND=MATCH is a capital-light add-on for compatible fixed-speed machines, it offers VFD-like savings without VFD-level complexity or cost. They can stabilise pressure, reduce specific energy consumption, and improve uptime on their installed base, accelerating the shift toward smarter, energy-optimised compressed air system.

Since undetected air leaks can erode both energy efficiency and system lifespan, what’s enabling greater adoption of automated leak detection tools among Indian SMEs?

Undetected leaks can easily waste 20–30 percent of a plant’s compressed air, forcing compressors to run longer, raising energy bills and shortening equipment life. For Indian SMEs working on thin margins, that combination of avoidable cost and reliability risk is a powerful trigger to adopt smarter, automated leak-detection tools.

On the technology side, modern ultrasonic detectors, acoustic leak cameras and IoT flow and pressure sensors have become simpler and more affordable. They can ‘see’ and log leaks even in noisy workshops, automatically map and quantify losses, and generate clear repair lists and reports without shutting the line down. Cloud dashboards and mobile apps mean a small maintenance team can monitor multiple lines and schedule repairs based on data rather than guesswork.

Economically, this delivers quick payback. Fixing leaks cuts electricity consumption, frees up compressor capacity for future growth, and reduces unplanned stops caused by pressure drops. At the same time, growing focus on energy efficiency, ISO 50001-style energy management and government-backed efficiency programs is nudging SMEs to measure and reduce compressed-air waste. Taken together, smart tools, hard savings on power, and soft pressure from customers and regulators are all driving faster adoption of automated leak-detection solutions among Indian SMEs.

With global customers demanding ESG-aligned operations across the supply chain, how are green compressed air systems supporting sustainability targets in Indian export manufacturing?

Global supply chains increasingly expect ESG-aligned performance from Indian export manufacturers, with sustainability now directly influencing contract eligibility, vendor ratings, and access to premium markets. Advanced compressed air systems play a measurable role in helping manufacturers meet these expectations by reducing electricity consumption, emissions, and operational waste.

Technologies such as high-efficiency permanent magnet motors, ELGi’s Demand=Match system, and eco-optimised package designs significantly improve energy performance and lower carbon intensity. Oil-free and low-maintenance compressors further help eliminate contamination risks while supporting compliance with global ISO standards for air quality and environmental management.

By integrating these advanced systems, manufacturers can credibly report reduced resource footprints, strengthen ESG scorecards, simplify sustainability disclosures, and simultaneously lower operating costs, delivering both compliance and competitive advantage in export-driven markets.

As compressed air systems evolve into intelligent infrastructure within smart factories, what role will AI and automation play in optimizing air efficiency over the next five years?

Looking ahead, the next five years will redefine industrial competitiveness, AI and automation will be foundational in driving energy savings and reliability across compressed air infrastructure in smart factories. Solutions like our Demand=Match system use real-time analytics and automated controls to ensure air supply matches shifting demand, which eliminates unnecessary cycling and typically delivers up to 17 percent energy reduction. IoT-powered platforms, including air alert, offer users real-time visibility and predictive maintenance alerts, reducing downtime and maintenance costs.​  

Furthermore, AI automation enhances zero-waste operations, optimizes material use, and supports circular economy goals through smarter parts dispatch and resource planning. Oil-free compressor designs and recovery systems, managed with AI-based controls, help cut environmental impact, amplify resource efficiency, and align with strict global sustainability standards. By embedding these technologies, manufacturers lay the foundation for sustainable, scalable operations that adapt easily to evolving market demands and ESG expectations.​