How Flowlogic Works
The Sullair Flowlogic system installs between your compressed air storage receivers and the plant distribution system. It uses a precision flow controller that decouples supply-side pressure from demand-side pressure fluctuations. Here's how it delivers results:
- Pressure/flow control: The Flowlogic controller maintains distribution system pressure within ±1 PSI regardless of demand fluctuations — eliminating the pressure swings that cause problems downstream.
- Supply-side pressure reduction: Because the controller buffers demand peaks, your compressors can operate at a lower average discharge pressure — typically 10–20 PSI lower than current setpoints. Every 2 PSI reduction in compressor discharge pressure saves approximately 1% in energy.
- Demand event management: When a large consumer — like a paint line, blow molder, or leak event — pulls a surge of air, the controller draws from upstream storage rather than forcing compressors to spike output. This prevents cascading pressure drops across the facility.
- Compressor cycling reduction: With stable system pressure and adequate storage, compressors spend more time in loaded operation and less time in wasteful unloaded cycling.
Typical Results
Facilities that install Sullair Flowlogic typically see energy savings of 10–25% on compressed air system operating costs. Additional benefits include reduced compressor wear, fewer pressure-related production quality issues, and more predictable system behavior. For a 100 HP compressor operating 6,000 hours per year, even a 15% energy reduction can represent $5,000–$8,000 in annual savings.
Brabazon engineers can audit your compressed air system and model the projected savings from a Flowlogic installation at your facility. Contact us at 800.825.3222 or online to get started.
