Assessment of Compressed Air System Efficiency in a Pharmaceutical Manufacturing Plant in Ogun State

Compressed air is classified as the fourth utility in pharmaceutical manufacturing, supporting tablet compression, packaging operations, and pneumatic conveying systems, yet compressed air generation is typically one of the most energy-intensive and inefficient utility systems in Nigerian manufacturing plants. This study assesses compressed air system efficiency in a pharmaceutical manufacturing plant in Sagamu, Ogun State, using a systematic compressed air audit following the Carbon Trust and Compressed Air Challenge audit methodologies. Air demand profiling was conducted using data loggers on the compressor control panels over a two-week period spanning normal and peak production shifts. Leak detection surveys were performed using an ultrasonic leak detector across the complete distribution network. System pressure mapping identified pressure drop hotspots, and specific energy consumption was calculated for each compressor unit. Findings revealed that compressed air demand variability exceeded 40 percent between peak and off-peak production periods, with existing fixed-speed compressors operating inefficiently during low-demand periods. Leak survey results identified 47 active leak points with an estimated aggregate wastage of 22 percent of total compressed air generation. Measured specific energy consumption of 0.21 kilowatt-hours per normal cubic metre exceeded the industry efficiency target of 0.13 by a significant margin. The study recommends installation of a variable-speed drive compressor for base load supply, systematic leak repair, and pressure regulation setpoint reduction as priority interventions. Keywords: compressed air audit, energy efficiency, pharmaceutical manufacturing, leak detection, Ogun State.