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Modernize Your Compressed Air System for Higher Performance
Older compressed air systems often consume more energy and require frequent maintenance due to wear, leaks, and outdated controls. Legacy Industries provides professional upgrades and retrofits for existing air compressor networks, dryers, filters, and piping systems. Each upgrade is engineered to improve flow, reliability, and efficiency while extending the life of your equipment.
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Why Upgrade Your Air System
| Issue | Impact | Legacy Solution |
|---|---|---|
| High energy consumption | Increased operating cost | Variable speed drives, sequencing, and optimization |
| Frequent downtime | Lost production hours | System modernization and preventive components |
| Pressure fluctuations | Poor tool performance | Balanced piping, storage, and controls tuning |
| Air leaks and restrictions | Wasted energy and noise | Leak detection and piping redesign |
| Outdated controls | Limited efficiency and visibility | Smart control systems with real-time monitoring |
An upgraded system provides stable pressure, cleaner air, and measurable savings month after month.
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Types of Upgrades We Provide
- Air compressor retrofits with modern controls and sensors
- Variable speed drive (VSD) conversions for energy efficiency
- Sequencer installation for multiple compressor systems
- Air dryer and filtration upgrades for improved air quality
- Piping system redesign and loop conversions
- Energy recovery and heat reclaim integration
- Leak reduction and pressure optimization programs
- Smart monitoring systems for maintenance tracking
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Step-by-Step Upgrade Process
1. System Evaluation
We conduct a full analysis of your current system, including pressure readings, flow mapping, and energy data collection.
2. Efficiency Audit
Using flow meters and pressure loggers, we determine energy losses, cycling frequency, and leak rates.
3. Design and Proposal
We present targeted upgrades with projected energy savings, payback period, and ROI analysis.
4. Implementation
Our technicians install new equipment, controls, or piping while minimizing production downtime.
5. Commissioning and Verification
After completion, we verify performance improvements and provide documentation for your records.
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Common Retrofit Applications
| Upgrade Type | Typical Benefit | Energy Savings Potential |
|---|---|---|
| Variable Speed Drive Retrofit | Match air output to demand | 20% to 35% reduction in energy use |
| Smart Sequencer Installation | Coordinate multiple compressors | 10% to 20% reduction |
| Piping System Optimization | Minimize leaks and pressure drop | 5% to 15% improvement |
| Dryer & Filter Upgrade | Reduce pressure loss and contamination | Better product quality and uptime |
| Heat Recovery Integration | Reuse waste heat from compressors | Up to 80% heat energy recovery |
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Control System Upgrades
Modern control systems provide precise pressure management and real-time data visibility. Upgrading to digital or smart controls helps optimize compressor sequencing, detect anomalies, and automate maintenance reminders.
Key Control Features:
- Touchscreen PLC-based interfaces
- Pressure band adjustment with remote access
- Data logging for energy audits
- Alerts for temperature, dew point, and pressure deviations
- Integration with facility SCADA or building management systems
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Piping and Distribution Retrofits
- Replace corroded black iron with aluminum or stainless steel piping
- Convert straight-run systems into closed-loop configurations
- Add properly sloped drains and moisture traps
- Install isolation valves for easier maintenance
- Resize main lines and drops for balanced airflow
These upgrades improve pressure consistency, reduce leaks, and make future maintenance safer and faster.
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Energy Optimization and Monitoring
- Add VFDs to modulate compressor output during low demand
- Install flow sensors and kWh meters for real-time tracking
- Lower system pressure by 5–10 psi to reduce energy waste
- Identify and repair leaks with ultrasonic testing
- Schedule compressor rotation to balance operating hours
Data collected before and after upgrades provides proof of savings and helps plan maintenance intervals.
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Safety and Compliance
- Follow OSHA and ASME B31.3 piping standards for all retrofits
- Use lockout and isolation procedures during installation
- Provide proper labeling for air, electrical, and condensate lines
- Supply full documentation and safety data sheets post-installation
- Perform system pressure testing before return to service
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Benefits of Modernizing Your Air System
- Lower electrical consumption and carbon footprint
- Reduced wear on compressors and motors
- Consistent pressure and cleaner air
- Easier maintenance with modular components
- Extended lifespan of existing infrastructure
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Frequently Asked Questions
Can upgrades be performed without downtime?
Yes. Many installations are staged during off-hours or weekends to avoid disrupting production.
Do you upgrade systems from any manufacturer?
Yes. We retrofit compressors, dryers, and controls from most major brands while maintaining warranty compliance.
How much can I save from upgrading?
Savings typically range from 15% to 40% depending on the age and condition of your current system.
Do you provide documentation for energy rebates?
Yes. We provide before-and-after reports and verification data for utility rebate submissions.
Can you integrate monitoring with our existing network?
Yes. We configure new control systems to connect with your existing building or plant monitoring network.
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Service Area
Legacy Industries performs compressed air system upgrades and retrofits across Greenville, Spartanburg, Anderson, Simpsonville, Laurens, and Gaffney, as well as Western North Carolina and North Georgia.
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Upgrade for Performance, Efficiency, and Reliability
Modernizing your compressed air system delivers measurable energy savings, improved uptime, and long-term operational stability. Legacy Industries is ready to evaluate, design, and install upgrade solutions that extend the value of your equipment and reduce your operating costs.
Phone: (864) 431 4670
Email: tyler.abbott@legacyind.net
Service Region: Upstate South Carolina and surrounding areas