Cost of a Clogged Filter
Three questions, one number: what a clogged air/oil separator element is costing you in wasted electricity every year.
Which element?
A clogged element is costing you about
€970
…every year in extra electricity — €80.85 per month, just to push air through a dirty filter.
Wasted electricity
6,468 kWh / year
Equivalent CO₂
1,940 kg / year
Extra energy
2.45 %
On the motor plate.
From your last bill — per kWh.
When did you last change the element?
A new separator sits around 200–300 mbar. Plan the replacement as it approaches 800 mbar. If you have a gauge reading, use exact figures below.
What it costs as the element ages
Why pressure drop costs energy
Every filter, separator and dryer between the compressor and the point of use eats a little pressure. To still deliver the pressure your machines need, the compressor has to run at a higher discharge pressure — and compressing air to a higher pressure takes more power. As an element loads up with dirt and oil, its pressure drop climbs, and so does your electricity bill, silently, every hour the compressor runs.
Typical pressure drops
| Element | Healthy | Service | Critical |
|---|---|---|---|
| Air/oil separator element | 200–300 mbar | above 500 mbar | above 800 mbar |
| Line filter (downstream) | 100–300 mbar | above 350 mbar | above 500 mbar |
| Air intake filter | 10–25 mbar | above 35 mbar | above 50 mbar |
This is an estimate based on widely used rules of thumb: about 7% more energy per bar of additional pressure on the discharge side; about 2% per 25 mbar of restriction on the intake side. CO₂ assumes 0.30 kg CO₂ per kWh, the EU grid average. Real savings depend on the compressor design, the control type (load/unload, variable speed) and how the system is operated.
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