Worked example: off-shift air demand in a dairy plant
Consider a dairy plant with continuous production, cleaning cycles, and compressed air demand outside production hours. This scenario explains an assessment method, not a measured client result.
The operating question
How much demand remains when production stops, and is the header pressure higher than the critical processes require? Cleaning, packaging, and instrument loads must be distinguished from leakage before interpreting the off-shift baseline.
What to measure
Pair power, pressure, and flow logging with production records and an ultrasonic or acoustic imaging survey. Tag accessible leaks with their location and estimated flow, and check air-quality and minimum-pressure requirements with the plant's quality and operations teams.
Changes to evaluate
Rank leak repairs and control adjustments by expected savings, access constraints, and process risk. Estimate costs using the plant's actual energy rate and operating schedule; obtain utility approval before work when the applicable program requires it.
How an outcome would be established
Recheck repaired locations and repeat the metered baseline under comparable production and cleaning conditions. Document the measurement period, remaining leaks, changes in production, implementation costs, and annualization assumptions. Utility eligibility is a separate program decision.
This is an educational scenario, not evidence of a completed client engagement or guaranteed savings. Facility recommendations require measured data and documented assumptions.
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