Case Study: Ingersoll Rand achieves dramatic energy and cost savings on compressed-air production with AVEVA (Wonderware InTouch HMI)

A New Compressor Management System Dramatically Cuts Energy Consumption for Compressed Air Production

Ingersoll Rand, a global leader in centrifugal compressors, needed to cut energy consumption and optimize equipment management across proprietary and third‑party compressors while identifying and predicting compressed‑air demand. To address this, they adopted AVEVA’s platform, deploying Wonderware InTouch HMI as the supervisory solution to integrate with existing PLCs and Modbus‑compatible equipment.

AVEVA’s Wonderware InTouch enabled real‑time visualization, monitoring of more than 90 compressor parameters, individual on/off control driven by actual demand, and predictive remote diagnostics—eliminating manual checks and minimizing waste. The implementation delivered measurable results: roughly €8,000/month energy savings at one customer (ROI ~9 months), contributed to aggregate savings equivalent to avoiding 15,000 tons of CO2 (≈€1.6M), and improved reliability and maintenance through early fault detection.

Ingersoll Rand

Luca Ferrari

Energy Air Audit Specialist