A UK manufacturer cut pumping energy costs by nearly £1 million in a single year by replacing compressed air-driven pumps with high-efficiency electric alternatives.

Rising energy costs and sustainability targets are forcing manufacturers to rethink how critical systems are powered. One of the biggest hidden energy drains is compressed air.

Air-operated diaphragm pumps (AODDs) are commonly used across UK manufacturing sites due to their versatility and durability. However, their reliance on compressed air makes them inherently inefficient – typically operating at just 10–15% efficiency.

This case study shows how switching to electric diaphragm technology delivered immediate and scalable benefits for one of our customers.

The Challenge

A national corrugated packaging manufacturer relied heavily on air-operated diaphragm pumps (AODDs) for continuous production across multiple sites.

However, this created three key issues:

• High energy costs driven by compressed air usage
• High maintenance burden due to exhaust icing (caused by moisture in the pump) and air valve wear
• Limited visibility of true operating costs, as air usage wasn’t closely tracked

The business needed to reduce energy consumption – without disrupting production.

The Solution

Initially, CDR Pumps proposed a controlled trial:

• Replace one AODD pump with a like-for-like QUANTM electric diaphragm pump
• Measure real-world performance by comparing the air consumption of an AODD with electrical usage  on the QUANTM unit

The QUANTM pump was selected because it:

• Eliminates the need for compressed air
• Operates at up to 80% efficiency
• Fits within existing system footprints with minimal modification

The Initial Results

The impact from a single pump was immediate:

Calculated using a conservative cost of £0.21 p/kWh.

Scaling the Impact

Following the successful trial:

• We supported the commissioning and installation of seven QUANTM pumps at one site
• We monitored average energy usage per pump during operation
• Annual site savings reached £70,248
• Energy consumption reduced by 334,687 kWh/year

We subsequently supported further rollout across 11 sites:

• 96 QUANTM pumps were installed
• £980,000 saved in the first year

Operational Benefits Beyond Energy Savings

The transition also delivered measurable operational improvements:

• No exhaust icing (having eliminated compressed air dependency)
• Lower noise levels
• No dry running issues (due to automated priming)
• Reduced maintenance requirements
• Improved reliability and uptime
• Integrated controls enabling easier automation

Strategic Outcome

What began as an energy-saving initiative became a broader operational upgrade, delivering:

• Lower total cost of ownership
• Reduced CO₂ emissions
• Improved process reliability
• A scalable solution across multiple sites

A relatively simple equipment change delivered transformational impact.

Key Takeaway

Electrification isn’t just a sustainability initiative – it’s a commercial advantage.

By replacing compressed air systems with efficient electric alternatives, manufacturers can achieve:

• Immediate cost savings
• Greater operational resilience
• Measurable progress towards decarbonisation

If you’re evaluating pump efficiency on your site, we can help you quantify the opportunity.