22 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Process, Controls & Plant Focus on: Compressed Air centralised controls, we were able to replace all 16 units with just two, supported by a more efficient piping layout,” explains Hewitt. “The result wasn’t just lower energy use, but better reliability and improved air quality in production.” The investment, he says, will pay for itself in under three years. “That’s not unusual when you take a systems-based approach. It’s often not the compressor itself that’s the problem - it’s the way the entire system is designed.” He also points to low-cost measures that can deliver high impact, such as leak detection, pressure reduction, and using waste heat from compressors to offset heating demands elsewhere on site. The technology is there - but awareness lags Technological advances have made it easier for businesses to monitor and manage energy use, but Hewitt believes adoption is still patchy. “We’ve worked with Bluetooth-connected controllers that allow real-time monitoring of system performance - things like pressure fluctuations, load profiles, energy consumption,” he says. “That kind of visibility is hugely valuable. But many companies still don’t realise it’s an option.” He highlights energy recovery systems as one of the most underused tools. “Compressors produce a lot of heat. With the right setup, up to 90% of that can be recovered and used for heating water or buildings. It’s effectively free energy that’s otherwise lost.” Hewitt is also keen to stress that compressed air suppliers shouldn’t just talk about efficiency— they should demonstrate it themselves. At Anglian’s own facility, a 64-kilowatt solar PV system has been installed, paired with a battery storage unit that allows the company to use most of its own generated electricity on site. “We’ve also transitioned our vehicle fleet to electric and installed smart lighting systems throughout our offices,” says Hewitt. “It’s not about optics it’s about operational logic. These are measures we’d recommend to customers, so it makes sense to do them ourselves.” While Anglian’s growth has coincided with advances in compressor technology -particularly through its longstanding relationship with manufacturer Atlas Copco - Hewitt believes continuity and training have played a larger role. “We’ve got a very low staff turnover, which is rare in this kind of technical field. That means we’ve built a strong level of expertise in-house, and customers trust us to guide them through quite complex decisions.” Rather than focusing on product innovation for its own sake, Hewitt says the company’s priority is practical benefit. “There’s always a new product on the horizon. The challenge is understanding where it fits and where it doesn’t. We try to stay grounded in what the customer actually needs.” Starting the process For companies that haven’t previously considered compressed air as part of their energy strategy, Hewitt recommends starting with data. “An energy audit is the first step. Often, businesses don’t know where they’re losing energy—or how much. A simple pressure test or thermal imaging scan can uncover issues that are costing thousands of pounds a year.” He adds that energy efficiency needs to be a shared goal. “It can’t just sit with facilities or procurement. Everyone—from finance to operations - has a role in reducing energy use. Culture matters as much as technology.” The Road Ahead Looking ahead, Hewitt expects compressed air systems to play a growing role in industrial decarbonisation strategies. “As businesses set net-zero targets, they’ll need to look at every part of their energy usage. Compressed air may not be glamorous, but the gains are real and measurable.” He’s optimistic about what’s next. “It’s an area where you can achieve environmental and financial wins at the same time. That’s rare - and it’s why I think we’ll see much more attention focused here in the next few years.”
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