The ChallengeMonitoring Systems
The Southern Illinois plant operated two compressor rooms on opposite sides of the facility with five compressors running independently. Without centralized visibility, compressors cycled inefficiently, driving up electrical consumption and limiting operational control. Plant leaders needed a system capable of coordinating equipment performance across the entire operation.
The AssessmentA Roadmap to Savings
Brabazon evaluated the compressed air setup and identified an opportunity to actively manage compressor sequencing based on real-time demand. The solution focused on automation, visibility and remote oversight to reduce unnecessary run time while supporting consistent air delivery. A monitoring strategy emerged as the most effective path to measurable energy reduction.
The ResultVerified Savings Surpass Projections
Brabazon installed a monitoring system designed to automatically turn compressors on and off to match fluctuating demand across both compressor rooms. Remote system monitoring helped Brabazon to quickly alert plant personnel of issues, supporting higher uptime and operational stability. The project delivered verified annual energy savings of $28,000 from 404,228 kWh reduced usage, along with a $29,670 utility rebate from Ameren. The electricity saved equaled enough power to supply 37 homes for one year.
Beyond a Single Project Your Partner in Sustainable Efficiency
Since 1978, Brabazon has supported manufacturers across the Midwest with advanced compressed air, pump and vacuum solutions. Monitoring systems represent one part of a broader approach focused on innovation, efficiency and long-term performance improvements. Each project centers on practical technology strategies designed to reduce operating costs and strengthen energy management programs.