Compressor Controller ROI Calculator
Estimate energy savings for your compressor system.
Choose compressor horsepower, number of compressors, and daily run time. Click a bar in the HP comparison to load that size. In the savings breakdown, hover over a category to highlight its share in the chart.
Use the motor horsepower printed on the compressor nameplate.
Use the count of similar compressors this estimate should include.
Savings breakdown
Hover over a category to highlight the matching part of the chart. The total annual savings stays fixed in the center.
Each category shows an estimated share of the annual savings total. Hovering does not change the number in the middle. It only highlights the matching section of the chart.
Quick HP comparison
Click any bar to make that compressor size the active scenario in the calculator.
Savings range by compressor size
Conservative, average, and strong-fit estimates using the same built-in assumptions.
| Compressor HP | Annual cost now | Conservative | Average | Strong-fit | Payback |
|---|
Show your work: formulas and assumptions used
These formulas are shown so a customer can understand what the estimate is doing. The constants are planning assumptions, not a guarantee. For an audited ROI, replace these with measured kW, runtime, electric rate, compressor loading, dryer power, filter pressure drop, and actual installed price.
This calculator is provided for general informational and preliminary budgeting purposes only. Results are estimates based on simplified assumptions and user-entered information. They do not constitute a performance guarantee, binding offer, engineering study, utility savings guarantee, or contractual commitment. Actual results may vary materially based on compressor type, control strategy, load profile, pressure setpoints, leakage, maintenance condition, dryer type, filter pressure drop, moisture load, ambient conditions, maintenance practices, utility tariff structure, and installation quality. Users should independently verify all assumptions and results before making purchasing, budgeting, engineering, or operational decisions.
Converts the daily runtime slider into annual operating hours.
annual run hours = run hours/day × 20 days/month × 12 months/year
Horsepower is converted to kW using 0.746 kW per HP. The 1.10 factor allows for typical service-factor/loading allowance, then the result is divided by assumed 70% motor/system efficiency.
estimated kW = compressors × HP × 1.10 × 0.746 ÷ 0.70
Uses the estimated kW, annual runtime, and a baked-in $0.14/kWh electric rate.
annual energy cost = estimated kW × annual run hours × $0.14/kWh
The base controller improvement range is modeled at 20%–34%, with 27% used as the average planning case.
base average savings = annual energy cost × 27%
Dryer/filter impact is modeled as a 5% average uplift. The displayed range uses 3%–8% to reflect different dryer loads, filter pressure drop, and treatment-side losses.
dryer/filter impact = annual energy cost × 5%
The main savings number combines the average controller case and the average dryer/filter impact.
average annual savings = annual energy cost × (27% + 5%) = annual energy cost × 32%
The low end combines 20% base savings and 3% dryer/filter impact. The high end combines 34% base savings and 8% dryer/filter impact.
savings range = annual energy cost × 23% to 42%
Payback uses an included planning cost of $800 per compressor. This cost is hidden from the input section to keep the calculator simple.
payback months = ($800 × compressors) ÷ average annual savings × 12
Confirm compressor load/unload behavior, actual kW draw, leaks, system pressure, dryer type, dryer kW, filter differential pressure, drain behavior, annual run schedule, and electric rate.
measured data should replace assumptions whenever available