Product
Model the compressed air system as it actually operates.
Build the system from the compressor room to the points of use. Add operating schedules and changing demand. Calibrate the model against measurements from the real plant. Then test changes and compare what happens to pressure, flow, compressor operation, energy use and annual cost.
System canvas
The demo plant as drawn in the app. Click any component: its parameters, its flows, its share of the bill.
01 — Build
Build the system you actually have
Draw the compressed air network from supply to demand. Add the components, pipework and consumers that determine how the system behaves — then enter the specifications you know.
Compressors
Fixed-speed and VSD machines — capacity, power characteristics, pressure bands and load/unload control settings.
Receivers & storage
Storage volume, pressure limits, and where the receiver sits in the network — central, or local at a heavy consumer.
Pipes & fittings
Lengths, diameters and layout — the pressure losses that make pressure at the machine different from pressure at the compressor.
Dryers & filters
Pressure drop in the line and purge consumption — the system losses your energy bill is already paying for.
Consumers & demand
Steady machine demand, cyclic tools with duty cycles, intermittent loads — each with its own flow, pressure requirement and operating pattern.
Leaks & blow-offs
Place leaks where they are — or where you suspect them — with estimated or measured losses, and see what each one costs.
02 — Operate
Your plant doesn't have one operating point
Production changes by shift, day and operating mode. CasPro lets you define the demand patterns your plant actually runs — then tests the system across all of them.
Each operating mode can have its own consumers and demand profile. CasPro checks pressure and system behaviour for each condition, and combines the schedule into annual energy use and cost.
Operating schedule · week
rolls up to 6,000 h/yr
MON–FRI
SAT
SUN
■ full demand
■ partial demand
■ reduced
■ standby
Every mode is checked: enough pressure at every point of use, at that mode's demand — not just on the average day.
03 — Calibrate
Make the model match the real plant
A model is only useful if it behaves like the system you're modelling. So measure what's happening in the plant — and enter the measurements into CasPro.
STEP 1
Measure in the plant
gauge, stopwatch, clamp meter
STEP 2
Enter the readings
guided, with the formula shown
STEP 3
CasPro works backwards
pressure losses, capacity and power adjusted to match the measurements
STEP 4
The model behaves like your plant
every parameter keeps its provenance
Pressure measurements
Compare measured and modelled pressure at known points in the network — and pull the model's losses into line with reality.
Pump-up test
Time the receiver filling — the compressor's actual delivered capacity, not the nameplate's.
Load/unload timing
A stopwatch on the cycle — measured cycling refines compressor capacity and average plant demand together.
Current / power measurement
Loaded and unloaded readings — compressor power calibrated against what the machine actually draws.
Shutdown leak test
Production off, watch the pressure decay — the plant's total leak load, measured instead of guessed.
Pipe & component pressure drop
Upstream and downstream readings at known flow — the real resistance of a line, a filter, a dryer.
Now when you test a change, you're not comparing it against a generic system. You're comparing it against a model calibrated to yours.
Every calibrated parameter keeps its provenance — nameplate, manual, calibrated or locked — with one-click revert. A measurement never silently changes your model.
Coming to Consultant: whole-system calibration from a plant pressure survey — walk the plant with a gauge, and the model fits itself to what you measured.
04 — Test
Change anything. Compare what happens.
Duplicate the baseline and change the decision you're considering: replace a compressor, add a VSD, change pressure settings, resize a receiver, repair leaks, change pipework, alter demand — or combine several changes.
Run the same operating schedule again and compare the scenarios side by side.
A lower energy bill isn't automatically a better system. CasPro shows the operational consequences alongside the savings — so you can see whether the change still maintains the pressure and behaviour the plant needs.
| Baseline | VSD retrofit | Lower setpoint | |
|---|---|---|---|
| Energy cost, €/yr | 31,355 | 24,868 | 28,883 |
| Δ vs. baseline | — | −6,487 | −2,472 |
| Specific power, kW/(m³/min) | 6.96 | 5.51 | 6.42 |
| Compressor starts, /h | 60 | ~1 | 60 |
| Min. point-of-use pressure, bar | 5.91 | 6.41 | 5.40 ⚠ |
The demo plant at €0.25/kWh · 6,000 h/yr. The setpoint option saves €2,472/yr — and drops the minimum point-of-use pressure to 5.40 bar. If your most sensitive machine needs 5.5, that saving just broke production. Both facts, on the same screen.
05 — Compare & decide
See what changed — and why
System performance
Pressure at every point of use, pressure and flow traces at every node, compressor cycling, starts per hour, storage behaviour — the operating picture, not just a total.
Energy & cost
Compressor power, specific power in kW/(m³/min), energy consumption per operating mode, and annual operating cost at your tariff and hours.
Air balance
Where the air goes: productive demand vs. leaks vs. dryer purge vs. storage changes. Usually the first genuinely surprising output — and the backbone of any audit.
Scenario comparison
Baseline versus every alternative — energy, cost and operational consequences side by side, with every assumption stated. Export it as a report; on Consultant, under your own brand.
Under the hood
What CasPro is calculating underneath
Compressed air systems change continuously. Compressors load and unload, receivers fill and empty, demand shifts, pressure moves through the network, and downstream consumers interact with upstream control.
CasPro models that behaviour over time, rather than reducing the plant to a single averaged operating point. That's where cycling, starts and point-of-use starvation come from — and they're usually where the money is.
The engine
The CAS Independent Physics Engine
- Validated against closed-form solutions — receiver fill, pipe pressure drop, leak decay
- Mass-balanced on every run — the air balance is a report you can read
- Every number carries its inputs and assumptions
Bring us a real system
Access is currently open to a small group of compressed air professionals. Bring a real plant or project, and we'll build and calibrate the first model with you.