Why include unloaded power?

Many compressors draw material power while producing little useful air during unloaded operation. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.

Is demand charge always added?

No. Add only the portion attributable or allocated under the site's tariff and approved costing method. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.

Can horsepower replace measured kW?

Not for decision-grade cost. Input electrical power and control behavior determine energy consumption. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.

What output should enter job cost?

Use total allocated compressor cost for the same production interval, then avoid adding its components again. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.

Why are unloaded power and demand charges excluded?

They require operating-profile and tariff information that many job estimators do not have and were making the page unnecessarily difficult. This version intentionally calculates marginal loaded energy. For full cost allocation, add measured unloaded kWh and the appropriate share of billing demand using the facility's actual tariff.

Can I use motor nameplate kilowatts?

Use measured input power or reliable controller data when possible. Nameplate power describes a rating, not the actual electrical draw at your loaded condition, and it can overstate or understate consumption. If it is the only available value, label the result as a preliminary screening estimate.

Abrasive Blasting, Shot Peening & Surface Prep calculator

Abrasive Blast Compressor Energy and Demand Cost Calculator

Estimate the electrical cost of blast compressed air with four values: measured loaded compressor power, loaded blasting hours, energy price and accepted area produced. The calculator reports loaded energy, total modeled energy cost and cost per accepted square foot. Unloaded operation and demand charges are fixed at zero in this streamlined version, making the result a transparent marginal-energy estimate rather than a full utility-bill allocation. Use it for job comparison, improvement studies and early costing. Facilities with significant unloaded power, demand charges or shared compressors should use the detailed meter and tariff data outside this four-field screen.

What this calculator does

Cost loaded and unloaded compressor energy separately and add only the documented share of utility demand charge.
Use it for energy cost allocation, shutdown-control business case, quote utility input, comparing the energy intensity of two nozzle, pressure or production-rate conditions..
Cost loaded and unloaded compressor energy separately and add only the documented share of utility demand charge.

Formula used

Energy cost = loaded compressor power × loaded hours × energy rate; accepted-area cost divides that amount by conforming square feet.
Fixed secondary assumptions compiled into this release: Unloaded compressor power: 0 kW; Unloaded hours: 0 hr; Billing demand: 0 kW; Demand rate: 0 $ / kW; Demand charge allocated to blasting: 0 %.

Inputs explained

Loaded compressor power: Measured average input power while supplying blast demand.
Loaded hours: Hours at loaded blast power during the cost interval.
Energy rate: Applicable marginal or blended energy rate.
Accepted blast area: Accepted area produced during the cost interval.

How to use the result

Best suited to energy cost allocation, shutdown-control business case, quote utility input, comparing the energy intensity of two nozzle, pressure or production-rate conditions..
The four-input result is conditional on the disclosed fixed assumptions; use a detailed engineering model when they are not representative. Does not model compressor control dynamics. Taxes, riders, and time-of-use tiers require tariff-specific extensions. Allocation is not the same as measured incremental demand. Shared-load allocation, power factor, demand ratchets, taxes and time-of-use pricing are outside this result.

Current U.S. benchmarks

As of May 2026, industrial electricity averages 8.7 cents per kWh across the U.S. (EIA), up 5.1% from a year earlier. State averages range widely, so plants should confirm against their own tariff.

Common questions

Why include unloaded power? Many compressors draw material power while producing little useful air during unloaded operation. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.
Is demand charge always added? No. Add only the portion attributable or allocated under the site's tariff and approved costing method. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.
Can horsepower replace measured kW? Not for decision-grade cost. Input electrical power and control behavior determine energy consumption. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.
What output should enter job cost? Use total allocated compressor cost for the same production interval, then avoid adding its components again. The fixed secondary assumptions are listed on this page and in the downloadable workbook so the four-input result remains auditable.
Why are unloaded power and demand charges excluded? They require operating-profile and tariff information that many job estimators do not have and were making the page unnecessarily difficult. This version intentionally calculates marginal loaded energy. For full cost allocation, add measured unloaded kWh and the appropriate share of billing demand using the facility's actual tariff.

Last reviewed 2026-08-24.