For decades, compressed air systems were treated as fixed infrastructure, installed once, maintained when necessary, and rarely reconsidered unless a failure occurred. That mindset is beginning to shift, particularly among mid-sized U.S. manufacturers facing rising energy costs, tighter production schedules, and increasing pressure to improve operational efficiency.

Compressed air can account for up to 30% of a manufacturing facility’s total electricity consumption, according to industry estimates. Yet many systems in use today were designed for operating conditions that no longer exist. As energy prices fluctuate and production lines demand higher uptime, manufacturers are starting to reassess whether legacy compressed air solutions still make economic sense.

From Capital Expense to Operational Strategy

Historically, purchasing decisions around compressors has focused heavily on upfront capital cost or brand familiarity. Increasingly, however, manufacturers are looking at compressed air as a long-term operational strategy rather than a one-time equipment purchase.

“Energy efficiency, system reliability, and lifecycle cost are now central considerations,” said industry analysts tracking industrial equipment purchasing behavior. “Mid-market manufacturers, in particular, are reassessing systems that quietly drain energy and require frequent maintenance.”

This shift has opened the door for global suppliers that combine industrial-scale manufacturing with flexibility and cost-performance balance without the premium pricing structures typically associated with legacy OEMs.

A Growing Role for Global Challenger Brands

One example is Hertz Kompressoren, a global manufacturer of industrial compressors and compressed air systems operating in more than 130 countries. While long established in Europe and other international markets, the company has been expanding its focus on the U.S. mid-market manufacturing segment.

Hertz Kompressoren offers rotary screw, piston, scroll, and turbo compressors, along with dryers, filtration systems, nitrogen generators, and gas compressors. Its approach emphasizes energy-efficient design, durable components, and compliance with U.S. pressure vessel and electrical standards, key requirements for American manufacturing facilities.

Rather than positioning compressed air as a premium, high-margin product category, the company aligns its systems around total cost of ownership, targeting manufacturers seeking measurable efficiency gains without unnecessary complexity.

Why the Mid-Market Is Driving Change

Mid-sized manufacturers often operate under tighter financial and operational constraints than large multinational plants. Unlike major corporations that can absorb inefficiencies, these companies feel the impact of energy waste and downtime more directly.

“Mid-market manufacturers are more willing to reconsider long-standing supplier relationships if performance or service expectations aren’t being met,” said one industrial procurement consultant. “They’re pragmatic. They want reliability, efficiency, and support without paying for features they don’t need.”

This pragmatism is reshaping buying behavior, encouraging manufacturers to evaluate alternative suppliers with global manufacturing scale but more adaptable commercial models.

Service, Digitalization, and Lifecycle Support

Another factor driving reassessment is service and lifecycle management. Compressed air failures can halt production, making response time and aftermarket support critical. Manufacturers are increasingly prioritizing suppliers that invest in service infrastructure and digital tools that support predictive maintenance and faster issue resolution.

Hertz Kompressoren has been expanding its distributor network and deploying digital partner platforms, including ERP and CRM integrations, to improve coordination with regional service providers. These tools enable closer collaboration and data-driven support capabilities that mid-market manufacturers increasingly expect.

Looking Ahead

As U.S. manufacturers modernize facilities and confront rising operational costs, compressed air systems are no longer escaping scrutiny. What was once considered background infrastructure is now recognized as a strategic lever for efficiency and reliability.

For mid-market manufacturers, the shift is less about chasing the newest technology and more about finding balanced solutions, systems that deliver energy savings, operational stability, and long-term value. That recalibration is creating new opportunities for global suppliers positioned between legacy OEMs and low-cost alternatives.