Compressed air system modelling

Model your compressed air system. Test the changes. See the savings.

Draw your plant — compressors, receivers, pipes, dryers, consumers, leaks — then compare changes: a VSD retrofit, a different pressure setting, a bigger receiver, a fixed leak. See the effect on energy use, pressure and annual cost before you make the decision.

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Live demo · the demo plant

6 m³/min screw · 1 m³ receiver · 65 m pipe · €0.25/kWh · 6,000 h/yr

Energy cost

€/yr

Avg power

Specific power

kW/(m³/min)

Starts

Min point-of-use

bar

Receiver pressure trace

— baseline — what-if

Every number on this panel is engine output for this exact plant, at €0.25/kWh and 6,000 h/yr. In the app you change anything — pipe sizes, setpoints, machines — and re-run in seconds.

€2,037/yr

what one 3 mm leak costs

−€6,487/yr

a VSD retrofit on the right load profile

−€2,472/yr

running 0.8 bar lower

60 → 19 starts/h

a larger receiver — €0 energy, far less motor wear

One illustrative demo system · €0.25/kWh · 6,000 h/yr — the full example is below.

Worked example

One system. Five possible changes. Five very different answers.

Take a simple compressed air system: one fixed-speed compressor, a receiver, distribution piping and varying demand. Change one thing at a time, and CasPro shows what happens to energy cost and system behaviour.

Sometimes the answer is energy. Sometimes it's cycling, or pressure at the point of use. Sometimes it's honestly zero.

Change	Annual impact	What else changes
One 3 mm leak	+€2,037/yr	duty cycle up 6 points
VSD retrofit	−€6,487/yr	starts 60 → 1 per hour
Lower pressure 0.8 bar	−€2,472/yr	check point-of-use margin first
Larger receiver (1 → 5 m³)	±€0	starts 60 → 19 per hour
Receiver + control change	−€2,600/yr	the receiver unlocks the saving, not the tank itself

Illustrative model at €0.25/kWh and 6,000 operating hours per year. Your system will be different.

Use cases

What are you trying to work out?

Plant & maintenance engineers

"Is this compressor / VSD / pressure change actually worth it?"

Model the change on your own system before committing to the investment.

See a plant example →

Energy auditors & consultants

"What will this change save my client?"

Compare options on the client's actual system and turn the result into a clear before/after case.

See a consultant example →

Distributors & service teams

"How do I show the customer what this upgrade will do?"

Test the proposed change against the customer's system instead of relying on generic savings estimates.

See a sales example →

Why CasPro

Built for real compressed air systems

Model the system, not just one component. Compressors, receivers, pipes, dryers, filters, consumers and leaks interact as a system — so that's what gets modelled.
See more than energy savings. Compare energy use alongside pressure, cycling, motor starts and point-of-use conditions — the answer isn't always a €/yr number.
Independent by design. CasPro doesn't sell compressors or monitoring hardware. The calculation doesn't change depending on what equipment you choose.

By the team behind air-compressor-guide.com — independent compressed air knowledge since 2003.

See how the modelling works

From the analytic suite

Receiver pump-up vs. closed form: exact
Pipe Δp vs. Darcy–Weisbach: match
Choked leak decay vs. exponential solution: match
Mass conservation, every scenario: <0.01%

Have a real compressed air project?

We're working directly with a small group of engineers, consultants and compressed air professionals before the public launch of CasPro. Bring a real system or a decision you're working on — we'll help you build the model, test the options, and get to a useful result together.

In return, we ask for detailed, honest feedback from using CasPro on real work.

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