‘Ingersoll Rand Is Rapidly Scaling Solar, Onsite Renewables, And Green Power Contracts’
In an interaction with Energy Today, Mr. Vedamurthy Mallikarjunaswamy, Product Management Leader, Ingersoll Rand India, talks about the company’s role in green energy.
What role does an efficient compressed air system have in running an operation optimally? Can you explain the difference between an oil-free and oil-flooded air compressor
Compressed air is often called the fourth utility (after electricity, water, and gas).
A well‑designed efficient compressed air system ensures productivity & process stability, consistent pressure at point-of-use, stable flow during peak demand and reduced production interruptions.
Industries like textiles, pharma, automotive, food and beverages, petrochemicals, electronics and general manufacturing depend heavily on pressure stability for tools, actuators, instruments, and automation.
Compressed air is one of the largest energy consumers in any plant — up to 10–30% of total electricity depending on the industry. An efficient system helps reduce energy consumption, wasted leaks, load/unload cycling losses and heat loss. Every 1 bar drop in pressure saves ~7% energy, so efficiency = real money saved.
Optimized systems minimize moisture carryover, temperature swings & overloading. This increases compressor life, reduces service interventions, and improves uptime.
An efficient system ensures the right air purity required at each process step. In industries like food & beverages, pharma, electronics, chemicals, and paint shops, compressed air quality directly affects contamination risk, surface finish and safety compliance.
If we analyze the life cycle cost of compressor then the energy consumption consists of almost 85% of the cost with 7% to maintenance and 8% to initial cost. So, efficiency should be #1 value driver while deciding compressor to run the system optimally.
Oil Free v/s Oil flooded air compressor:
In Oil Free compressor, no lubricating oil enters the compression chamber. They use special materials/coatings (e.g; PTFE, ceramic), water injection, or dry screw stages. These compressors deliver “Class 0” or oil‑free air as per ISO 8573‑1 air quality. Ideally suited where oil contamination is unacceptable.
In case of Oil injected or Oil Flooded air compressors, the oil is injected into the compressor chamber for Lubrication, Cooling & Sealing. Oil aerosols are removed using filters, but traces of oil can remain (depending on filtration).
Oil Free compressors are better suited for applications like Pharmaceutical, Food & Beverage, Electronics manufacturing, Breweries, Medical & lab air, Textile (high-quality spinning & weaving), Chemical, Oil & Gas etc. whereas Oil Lubricated compressors are suitable for applications in General manufacturing, Automotive tools and assembly, Foundries, Machine shops, Pneumatic tools, Packaging etc.
While Oil Free Compressors eliminate risk of oil contamination, lower filtration requirements downstream & reduced product rejection risk it demands higher initial capital and maintenance costs, slightly lower efficiency as compared to oil-flooded in some ranges, Oil lubricated compressors require lower initial cost, higher efficiency in many segments, Robust and reliable but requires multiple filtration stages, higher risk of downstream contamination, more maintenance and pressure drop across the downstream clean up equipment.
Decision on which type to buy should be taken based on the type of application, air quality requirements and industry segments.
Can you explain your statement about industries being able to reduce their energy bills by 10-15% by improving compressed air efficiency? How much awareness is there about the possible savings in the wider industry?
Most industrial plants underestimate how energy‑intensive compressed air really is. U.S. Department of Energy (DOE) states that 10–30% of total industrial energy is often used to power compressed air systems. They also estimate that 30% of compressed air energy is lost to leaks and many plants fail to repair leaks, which amplifies waste.
Optimizing systems regularly yields 10–15% savings (conservative number) through Leak detection & repair, pressure optimization, using variable speed drive compressors, improving storage & distribution.
Of late awareness is improving in wider industry, and we see emphasis on energy efficiency, with that comes more adoption of Variable speed drive (VSD or Regulated speed) compressors. But still many treat compressed air as “free” once the compressor is installed while they should be cognizant of true energy, cost of compressed air, cost of leaks and cost impact of running at unnecessarily higher pressure.
IIoT, predictive maintenance, and VSD adoption are increasing attention. We see better awareness in Pharma, F&B & Electronics industries who are energy efficiency conscious. General manufacturing, Automotive & Fabrication industries may have moderate awareness; many still view compressed air as a “utility cost” rather than an efficiency opportunity.
Awareness level of energy savings in compressed air industry is very low compared to the potential of savings where there is huge opportunity. Very simple measures like arresting even smallest air leakages, cross ventilation to lower operating temperatures, lowering operating pressure can help save 10-12% of energy bills. For detailed savings air audits is very useful initiative to realize savings opportunities.
How soon can companies expect a return on their investments when they go for Ingersoll Rand air compressors?
While the exact payback period varies by system size, application and operating hours, most customers see a meaningful ROI within a short cycle due to IR’s energy‑efficient designs and performance services. Industry data shows compressed air is one of the highest-cost utilities in any plant, with up to 70% of a compressor’s lifecycle cost coming from energy (not capex).
Ingersoll Rand’s most energy‑efficient lineup includes the innovative E‑Series Oil‑Free compressors, as well as the Next Generation RS Series, which uses premium‑efficiency designs and VSD technology for lower energy consumption. Our high‑performance TURBO‑AIR NX Series centrifugal compressor delivers industry‑leading efficiency through optimized aerodynamics and low mechanical losses. In addition, IR’s advanced Permanent Magnet motor and Hybrid Reluctance motor technology (available in select high‑efficiency rotary compressors) enhances part‑load efficiency and reduces energy losses, further improving lifecycle performance.
Ingersoll Rand’s “Ecoplant” which is an advanced, cloud‑based compressed air monitoring and optimization platform uses real‑time monitoring, AI‑driven control, and dynamic system optimization to ensure compressors run only as much as needed, significantly reducing energy waste. By stabilizing pressure, detecting leaks, and automatically adjusting to production demand, it can cut compressed‑air energy consumption and operating costs while preventing downtime through proactive alerts.
What sets Ingersoll Rand products apart from similar products?
Ingersoll Rand is consistently recognized for robust, durable designs and a focus on practical, low‑maintenance engineering, making them a preferred choice for industries that need long operational life and dependable up time.
Compared to some other known brands, IR delivers mid‑to‑high performance at a more accessible price point, offering excellent value without compromising industrial‑grade reliability.
IR has an extensive global service network, making parts, maintenance, and support easier and more affordable than competitors.
Our product breadth is consistently highlighted as a competitive advantage. We offer one of the widest portfolios ranging from reciprocating, rotary screw, centrifugal, oil‑free rotary, vane compressors serving everything from automotive to heavy industrial to clean‑air applications.
IR’s self‑developed R‑Series air end and patented rotary screw technologies ensure consistent efficiency and reliability, directly competing with high‑end innovations from global brands. All our inbuilt VFD compressors come with HPM and HRM motors having energy efficiency of IE5 which has set benchmark for new levels of efficiency
Turbo‑Air NX Series deliver industry‑leading aerodynamic efficiency, ISO Class 0 oil‑free air, and lower total cost of ownership, giving IR a decisive competitive edge and the largest centrifugal compressor market share in India.
Can you talk about some of the innovations that Ingersoll Rand integrates in its products? How central is Eco-plant AI to the operations of these machines?
Our Turbo‑Air / NX Series integrates highly efficient aerodynamic components—optimized inlets, impellers, scrolls, and diffusers—reducing mechanical losses and delivering up to 5% better specific power compared to competitive centrifugal designs.
IR integrates Hybrid Permanent Magnet and Hybrid Reluctance motors with IE5 efficiency primarily in its rotary screw air compressors, both oil‑free and contact‑cooled VSD models which helps deliver high efficiency across the entire speed range. This technology is one of IR’s most significant efficiency innovations.
Oil‑free rotary compressors like the E‑Series are designed for exceptional energy efficiency, with optional heat‑recovery systems that unlock further savings.
Modern IR compressors integrate intelligent controllers like MXs and XS ‑Series enabling Real‑time performance insights, Remote monitoring, Automated pressure and load optimization. These systems maximize uptime and efficiency.
IR’s Eco‑Plant is becoming one of Ingersoll Rand’s core digital technologies, transforming the way compressed‑air systems are monitored, optimized, and controlled.
It uses real‑time monitoring, advanced analytics, and AI algorithms to dynamically adjust compressor operation based on demand, cutting energy waste, stabilizing pressure, and reducing emissions. The system detects Leaks, Inefficiencies, Early signs of equipment failure allowing proactive maintenance and reduced unplanned downtime.
Ecoplant automatically ensures compressors use only the electricity required which is a major source of cost savings for plants with multiple compressors.
Can you elaborate on Ingersoll Rand’s goal of reducing scope 1 and scope 2 emissions by 2030 and achieving net-zero emissions by 2050. How realistic is this goal when faced with the challenge of achieving industrial growth? What kind of innovations will help achieve the dual goals?
Ingersoll Rand has publicly committed to aggressive climate targets:
By 2030:
Reduce Scope 1 & Scope 2 emissions by 60% across operations.
Reduce customer Scope 3 emissions by >15% through more efficient IR products.
By 2050:
Achieve net‑zero greenhouse gas emissions across global operations (Scope 1 & Scope 2).
Transition to 100% renewable energy globally.
At IR, we believe the approach of Lead sustainably focusing on “grow & operate” sustainably. This is built into product strategy. Our growth sectors clean energy, life sciences, water, food, and other sustainable end markets, create business incentives aligned with emissions reduction. By 2030, over 25% of IR revenue is expected to come from products with sustainable attributes, demonstrating that growth naturally reinforces lower‑carbon offerings.
IR already powers 45 sites with renewable energy through solar and green contracts, a direct step toward reaching the 2050 renewable goal.
IR integrates multi‑layer efficiency improvements across its product range. The Turbo‑Air NX Series centrifugal compressors with optimized aerodynamics and low mechanical losses. RS‑Series energy‑efficient rotary screws with VSD, premium motors, and energy‑recovery systems. Oil‑Free rotary E‑Series/ES‑Series compressors with heat‑recovery capability for reduced plant energy use. IR’s Nirvana compressors use bearing‑free permanent magnet motors paired with VSD, offering which helps with up to 96% motor efficiency across all loads, eliminating mechanical losses (no belts, couplings, seals) & lower power consumption at startup. These help customers reduce emissions, supporting IR’s sustainability goals.
Every new IR product goes through a Design for sustainability checklist and methodology, focused on material efficiency, energy consumption, serviceability & lifecycle footprint. IR launched 80 new innovative, sustainability‑focused products in 2023 alone, showing how innovation is accelerating.
As part of the 2030/2050 roadmap, IR is rapidly scaling solar, onsite renewables, and green power contracts, already adopted at dozens of sites globally.
Our targets are realistic and our strategy shows that industrial growth and emissions reduction aren’t competing priorities, they reinforce each other through innovation.
