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Older compressed air systems often consume more energy and require frequent maintenance due to wear, leaks, and outdated controls.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Outdated controls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:Â (864) 431 4670
Email:Â tyler.abbott@legacyind.net
Service Region:Â Upstate South Carolina and surrounding areas
