Evaluating Lifecycle Costs for Water and Wastewater Treatment Blowers

When selecting blowers for water and wastewater treatment, understanding lifecycle costs is crucial to ensuring long-term efficiency and cost-effectiveness. This guide outlines key considerations and strategies for making informed decisions about blower technologies. After project funding and process applications, the next step is to compare and contrast Total Cost of Ownership (TCO) for various proposed solutions.

TOTAL COST OF OWNERSHIP (TCO) CONSIDERATIONS WHEN SELECTING A BLOWER

Blowers are often the largest energy consumers in wastewater treatment plants. It is important to evaluate not just the upfront capital costs but the long-term expenses associated with energy consumption, maintenance, and reliability. A comprehensive TCO analysis includes:
 
Capital Costs:

While initial costs matter, they are only a fraction of the overall lifecycle costs. Lower upfront costs often correlate with higher operational costs over time.  

 

 

Operating Costs:

A key determinant of power consumption, efficiency directly impacts operating costs. Inovair blowers achieve superior efficiency, translating to substantial energy savings.  

 

 

Maintenance Costs:

All blower technologies require routine maintenance, but some also require scheduled and unscheduled rebuilds, adding significant costs over the lifespan of the equipment.  

 

 

Installation Costs:

The complexity and expense of installation vary across blower technologies, with some requiring more extensive infrastructure and labor. The ability to be placed outdoors is a driving factor of the installation costs.

 

Reach out to our sales team to help you evaluate the Total Cost of Ownership for your project.

 

CAPITAL COSTS: RISKS TO BUDGETING

Capital costs refer to the initial purchase price of a blower system, including the equipment itself and any necessary installation expenses. While it may be tempting to focus solely on upfront costs, it’s important to consider price stability and overall value.

Inovair geared centrifugal blowers are competitively priced—less expensive than gearless turbo blowers, similar in cost to PD screw blowers, and slightly more expensive than rotary lobe blowers. However, price alone doesn’t tell the whole story. Many blower technologies are highly susceptible to market fluctuations, with costs shifting due to changes in political climates, tariffs, and raw material supply chain disruptions. This variability can create budget uncertainties and unexpected financial challenges for wastewater treatment facilities.

Because Inovair blowers are designed and manufactured in the U.S., pricing remains more stable and predictable. Domestic sourcing and production reduces exposure to global supply chain volatility, ensuring that project budgets remain accurate from initial quote to final purchase. By choosing Inovair, facilities gain not only a cost-effective blower solution but also the confidence of reliable, consistent, and competitive pricing.

Inovair is the only BABA-compliant, high efficiency blower, which can help you secure the lowest available funding costs. Learn more about how choosing BABA-compliant blowers can benefit you.


OPERATING COSTS: WHY ENERGY USAGE MATTERS


When evaluating blower systems, operating costs—particularly energy consumption—play a critical role in total cost of ownership (TCO). To achieve true energy savings and accommodate variability in plant loading and seasonal changes, it’s essential to compare multiple operating points rather than relying on a single efficiency metric. One of the most accurate ways to assess blower efficiency is by measuring wire-to-air performance, which accounts for the total energy input required to deliver air at the specified conditions. To ensure a fair and accurate comparison across different blower technologies, the ASME PTC-13 standard is the recommended method for measuring wire-to-air efficiency.
  • Energy usage is the largest operating expense for most wastewater treatment facilities and blowers typically consume the majority of energy.
  • Energy costs also dominate the lifecycle expenses of a blower, making efficiency a priority in your total cost of ownership analysis.
  • Blowers with the lowest capital costs are often older technologies and come with higher long-term operational expenses due to inefficiency and increased maintenance requirements.
  • Inovair’s Geared Centrifugal Blowers are designed to optimize energy efficiency while maintaining durability, resulting in a lower TCO over the blower’s lifespan.
Additionally, by selecting a blower with superior wire-to-air efficiency and proven long-term reliability, wastewater treatment facilities can reduce uncertainty with respect to rising energy costs over time.



MAINTENANCE COSTS: UNEXPECTED COST DRIVER

One of the most overlooked components of Total Cost of Ownership (TCO) is true maintenance costs, which are broken down into:

Routine Maintenance:

Routine maintenance includes the standard upkeep necessary to keep a blower operating efficiently. While some blower technologies require extensive service plans and expensive proprietary parts, Inovair has streamlined maintenance with just four simple components that plant staff can easily replace themselves. These off-the-shelf parts can be locally sourced, reducing both cost and lead times.

 

In contrast, many other blower manufacturers impose strict requirements that mandate purchasing replacement parts directly from them, often at a premium. Failure to do so can void warranties. Additionally, some blower technologies require periodic rebuilds, which can be both time-consuming and costly, adding an often-overlooked burden to long-term operating expenses.


Non-Routine Maintenance (Repairs):

Non-routine maintenance covers unexpected repairs due to external factors or design vulnerabilities. Events such as lightning strikes, flooding, foreign object damage, or even imperfect installation can lead to costly downtime. Certain blower designs are inherently more prone to failure and/or require more strict installation procedures, leading to increased repair frequency and added expenses.

A key concern is the use of proprietary components, which can dramatically increase the cost and lead time for repairs. In some cases, facilities may even need to rent a replacement blower while waiting for repairs, further increasing operational costs. Additionally, post-repair efficiency can be negatively impacted, affecting long-term energy savings.

Beyond direct maintenance costs, uptime and reliability are crucial to minimizing disruptions and ensuring continuous operation. Blowers with higher uptime and minimal maintenance needs provide significant cost advantages. The inherent durability of the product ensures smooth operation and long-term savings.

The location of a blower’s manufacturing and service facilities also plays a significant role in long-term maintenance costs. Many blower manufacturers are headquartered overseas, meaning replacement parts may need to be sourced from Germany, Korea, or other distant locations—leading to long delays. In some cases, the blower will need to be shipped to an overseas factory for service. In contrast, having access to domestic manufacturing and support ensures faster service, minimizing downtime and associated costs.

INSTALLATION COSTS MATTER TOO

Blower installation costs can vary widely depending on system complexity and site-specific requirements. Selecting compact, durable (outdoor installations permissible) solutions like Inovair's blowers can minimize installation expenses, reducing both labor and material costs.

Some blower technologies shouldn't be installed outside or require the construction of a canopy, increasing overall infrastructure costs. Additionally, other blower technologies require a strict installation procedure. This not only incurs up front costs, but also increases the risk of failure and/or the warranty being voided by the manufacturer.

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Please feel free to contact us if you have any additional questions on BABA, our products, or if you want to arrange a meeting time at WEFTEC to discuss your project(s).