Common Energy Wasters in Compressed Air Systems
If you're running a compressed air system in a manufacturing plant, you're probably wasting 20-40% of the energy you're paying for.
That's not a guess—it's what I find in plant after plant after plant.
Here's what that looks like in real dollars: A typical 100 HP compressor costs about $45,000 per year to run. That means you're throwing away $9,000-$18,000 annually on waste that's completely fixable.
Over 20+ years, I've audited hundreds of compressed air systems. The problems are almost always the same: leaks, excessive pressure, pressure drop, and poor control strategies. I call these THE BIG 4 Energy Wasters.
The good news? These are systematic, measurable, fixable problems. Most have payback periods under a year—some under 6 months.
Let me show you exactly where your money is going and what to do about it.
Energy Waster #1: Air Leaks (The Silent Money Burner)
This is the #1 energy waste I find in manufacturing plants. Not sometimes. Every single time.
The Numbers That Wake People Up
A 1/4" leak at 100 PSI wastes approximately:
- 100 CFM of compressed air
- 25 kW of electrical power (continuous)
- $2,500-$3,500 per year in electricity costs
Just one leak.
The typical factory I walk into has 20-30% total air loss from hundreds of small leaks scattered everywhere. On a 100 HP system (75 kW), that's:
- 15-22 kW wasted continuously
- 90,000-132,000 kWh wasted per year
- $9,000-$13,500 per year thrown away
And most plant managers have no idea.
Where I Find Leaks (In Order of Frequency)
1. Quick-Disconnect Couplings - #1 Culprit
These are the worst offenders. Every time you connect/disconnect, the seal wears a little. After hundreds of cycles, they leak significantly.
Where: Everywhere you have portable tools or flexible connections
Solution: Replace worn couplings ($5-15 each), or switch to better quality couplings
2. Threaded Fittings on Pneumatic Equipment
Vibration loosens fittings over time. Thread sealant deteriorates. NPT threads are tapered and inherently prone to leaks.
Where: Pneumatic cylinders, FRLs, manifolds, valve connections
Solution: Re-tighten or re-seal with proper thread sealant/tape
3. Old Rubber Hoses with Cracks
Rubber air hoses age, crack, and leak. Especially near fittings and in areas exposed to heat or chemicals.
Where: Tool hoses, pneumatic connections, temporary setups that became permanent
Solution: Replace aged hoses ($10-50 each depending on length)
4. Pneumatic Cylinders with Worn Seals
Cylinder rod seals and piston seals wear out from use. Air leaks past worn seals.
Where: Automated equipment, clamping systems, actuators
Solution: Rebuild cylinders or replace seals ($20-200 per cylinder depending on size)
5. Unused Drops - The "Ghost Leaks"
This one surprises people. Old equipment removed years ago, but the air drop is still connected and leaking.
Where: Empty wall drops, abandoned equipment locations, closed-off production areas
Solution: Cap or remove unused drops (free or minimal cost)
6. Pressure Regulators and FRLs
Diaphragms wear out, adjustment screws develop leaks, filter bowls crack.
Where: Point-of-use regulation, equipment supply lines
Solution: Rebuild or replace leaking units ($30-150 each)
7. Compressor Unload Valves
The compressor's own inlet valve can leak when unloaded, wasting air.
Where: Inside the compressor package
Solution: Rebuild or replace inlet valve/unloader ($200-800)
The Leak Detection Process
You can't fix what you can't find. Here's the systematic approach:
1. Get an Ultrasonic Leak Detector
Cost: $1,000-$3,000 for a decent unit
Payback: Weeks (seriously)
Ultrasonic detectors hear the high-frequency sound of air leaks that your ears can't detect. They work in noisy factories. They find leaks you'd never find otherwise.
Alternative: Walk around with a spray bottle of soapy water. Cheaper, but way more time-consuming and you'll miss 70% of the leaks.
2. Systematic Tagging
As you find leaks:
- Tag each one with location and estimated size
- Rate by severity (small/medium/large)
- Photograph for documentation
- Log into spreadsheet
Why: Track progress, prioritize repairs, justify costs
3. Fix Biggest First
Priority order:
- Large leaks (1/4" and up) - highest ROI
- Medium leaks (1/8" to 1/4")
- Small leaks (under 1/8")
- Unused drops and abandoned equipment
A single large leak can waste more air than 20 small leaks combined.
4. Re-Audit Quarterly
Critical: New leaks always develop. Equipment vibrates, fittings loosen, hoses age.
Schedule quarterly leak audits. Track total leak rate over time. This becomes a KPI for your compressed air system.
Measuring Leak Rate
The Shutdown Test (Most Accurate):
- Shut down all air-using equipment (weekend or shutdown period)
- Pressurize system to normal operating pressure
- Shut off compressor
- Measure pressure decay over time
Calculation:
- System volume (gallons) × Pressure drop (PSI) × Time (minutes) = Leak rate
Interpretation:
- Under 10% of compressor capacity = Good
- 10-20% = Average (typical factory)
- 20-30% = Bad (significant waste)
- Over 30% = Terrible (massive waste)
Example:
- 1,000 gallon system drops from 100 to 90 PSI in 10 minutes
- That's 10% pressure drop in 10 min = ~20% leak rate
- On a 100 CFM compressor = 20 CFM wasted = $5,000-$7,000/year
Cost vs Savings
Leak Detection Investment:
- Ultrasonic detector: $1,000-$3,000
- Labor for detection: 4-8 hours
- Repair materials (fittings, hoses, etc.): $200-$1,000
- Labor for repairs: 8-40 hours depending on number of leaks
Total cost: $2,000-$8,000 typical
Annual savings on 100 HP system:
- Reduce leaks from 25% to 10%: Save 15% = $6,750/year
- Reduce from 30% to 10%: Save 20% = $9,000/year
Payback: 3-15 months, often under 6 months
ROI: This is often the fastest payback of ANY energy efficiency upgrade.
Energy Waster #2: Excessive System Pressure (The "Just In Case" Trap)
The trap: "We run at 120 PSI to make sure everyone has enough pressure."
The reality: Most pneumatic tools need 90 PSI.
The Hidden Cost of Extra Pressure
Energy penalty: Every 2 PSI increase = approximately 1% more energy consumption.
Why? Higher pressure means:
- More compression work (more energy input)
- More air through every leak (higher pressure = more flow through holes)
- More wear on equipment
Real example:
- Plant running at 120 PSI
- Actual max requirement: 95 PSI
- That's 25 PSI overpressure
- Energy waste: ~12.5% = $5,625/year on 100 HP system
And all we did to fix it: Turn a dial.
Why Plants Run at Excessive Pressure
Reason #1: "That's what we've always done"
Setup years ago at 120 PSI. Nobody's questioned it since. Tools work fine. Why change?
Answer: Because you're wasting thousands of dollars per year.
Reason #2: Compensation for Pressure Drop
Plant has 20 PSI pressure drop from compressor to far end. Solution? Turn up compressor pressure.
Problem: This wastes energy throughout the ENTIRE system, not just at the far end.
Better solution: Fix the pressure drop (see Energy Waster #3)
Reason #3: One High-Pressure Application
Maybe you have ONE tool that needs 110 PSI. So the whole system runs at 120 PSI.
Problem: 99% of your air uses 90 PSI. You're over-pressurizing everything for one tool.
Better solution: Install a point-of-use booster pump for that specific application ($500-$2,000). Run main system at 100 PSI. Save thousands per year.
The Leak Multiplication Effect
Here's what most people miss: Higher pressure makes leaks worse.
Flow through a hole increases with pressure. Double the pressure, you don't double the flow—you get 1.4× the flow.
Example:
- 1/4" leak at 100 PSI: 100 CFM wasted
- Same leak at 120 PSI: 115 CFM wasted
Running 20% higher pressure:
- Wastes 10% more energy through compression
- Wastes 15% more air through leaks
- Combined effect: ~25% higher leak-related energy waste
Vicious cycle:
- Run at high pressure
- Leaks waste more air
- "Need more capacity"
- Buy bigger compressor
- Still wasting 25-30% through leaks
How to Optimize System Pressure
Step 1: Audit Actual Requirements
Survey every piece of equipment:
- What pressure do tools actually need? (Check nameplates, not assumptions)
- What's the actual minimum for production?
- Are there high-pressure exceptions?
Typical findings:
- Most pneumatic tools: 90 PSI minimum
- Assembly automation: 80-90 PSI
- Packaging equipment: 85-95 PSI
- Spray painting: 30-60 PSI (pressure regulated at booth anyway)
- High-pressure exceptions: Maybe 1-2 specific tools
Step 2: Identify Exceptions
For any high-pressure applications:
- Can you install point-of-use booster?
- Can you regulate down from a higher pressure source?
- Is high pressure actually required or just assumed?
Point-of-use boosters:
- Cost: $500-$2,000
- Boost 100 PSI to 150 PSI for specific tool
- Pays for itself in months vs running whole system at 150 PSI
Step 3: Lower System Pressure Gradually
Don't just drop from 120 to 90 PSI overnight. People will panic.
Smart approach:
- Drop 5 PSI (120 → 115)
- Monitor for problems
- Wait a week
- Drop another 5 PSI (115 → 110)
- Repeat until you're at optimal pressure
Target: Minimum reliable pressure + 5-10 PSI safety margin
Example: If actual minimum is 90 PSI, run system at 95-100 PSI.
Step 4: Measure Results
Track:
- Energy consumption (kWh)
- Production issues (any tools not working?)
- Compressor runtime
- System stability
Expected results:
- 5-10% energy reduction typical
- No production issues (if you sized correctly)
- More stable system (less pressure swing)
Real Example
Plant: Metal fabrication, 100 HP compressor
Before: 120 PSI system pressure
Audit findings: Max requirement was 95 PSI (impact wrenches)
Action: Lowered to 100 PSI (allows 5 PSI safety margin)
Results:
- Energy reduction: 10%
- Annual savings: $4,500
- Cost to implement: $0 (turned a dial)
- Payback: Immediate
- Side benefit: Reduced leak losses by ~10% (lower pressure = less flow through leaks)
Energy Waster #3: Pressure Drop in Distribution (The Hidden Energy Thief)
The problem: You're making 110 PSI at the compressor, but tools at the far end only get 85 PSI.
What you do: Turn up the compressor to 125 PSI to compensate.
What you're really doing: Wasting 7.5% of your energy (15 PSI ÷ 2 = 7.5%) throughout the ENTIRE system.
What Causes Pressure Drop
1. Undersized Piping (Most Common)
The Expansion Trap (I see this ALL THE TIME):
Year 1: Plant installs 1" piping for 100 CFM demand. Works great.
Years 2-10:
- Add new machines → tap into existing pipe
- Add production line → run branch from main
- Add packaging area → extend piping
- Add assembly station → another drop
Year 10: Original 1" pipe now feeding 5× the equipment it was designed for.
Result: Massive pressure drop. Far end gets 75 PSI instead of 100 PSI.
The Vicious Cycle:
- Operators complain: "Not enough air pressure!"
- Maintenance turns up compressor from 100 to 110 PSI
- Six months later: "Still not enough!"
- Turn it up to 115 PSI
- A year later: "We need more air!"
- Now running at 125 PSI to get 85 PSI at the far end
Why this costs money:
- Wasting 12.5% extra energy (25 PSI over target = 12.5%)
- Making all leaks worse (higher pressure = more flow)
- Wearing out equipment faster
- Still have the pressure drop problem—just masked it
Pipe Sizing Rule of Thumb:
Pipe Size | Max Flow (CFM) at 100 ft | Max Flow at 500 ft |
---|---|---|
3/4" | 30 CFM | 15 CFM |
1" | 60 CFM | 30 CFM |
1-1/4" | 100 CFM | 50 CFM |
1-1/2" | 150 CFM | 75 CFM |
2" | 300 CFM | 150 CFM |
3" | 750 CFM | 400 CFM |
4" | 1,400 CFM | 750 CFM |
Target: Maximum 1 PSI drop per 100 feet of pipe
2. Dirty Filters
Filters clog over time. Clogged filter = massive pressure drop.
Symptoms:
- Pressure gauge before filter shows 100 PSI
- Pressure gauge after filter shows 85 PSI
- 15 PSI drop across ONE filter
Common mistake: People forget to change filters. "It's automatic" mindset.
Solution: Change filters on schedule! Set reminders. Track differential pressure.
3. Dead-End Piping Layouts
Branch/Tree layout:
- Air flows through main line, branches off to each area
- Far branches are dead-ends
- Long pipe runs with cumulative pressure drop
- No redundancy
Problems:
- Highest pressure drop at farthest points
- Can't isolate sections without shutting down everything
4. Too Many Bends and Fittings
Every elbow, tee, reducer adds pressure drop. Multiply that by dozens of fittings...
Each 90° elbow = equivalent to 3-5 feet of straight pipe
Long pipe run with 20 elbows? You just added 60-100 feet of equivalent length.
Measuring Pressure Drop
What you need:
- Pressure gauges (accurate to ±1 PSI)
- Locations: Compressor discharge, main header at various points, far ends of plant
Target: Maximum 10 PSI total drop from compressor to farthest point of use (5 PSI is ideal)
What I typically find: 15-25 PSI drop (way too high)
Solutions to Pressure Drop
Solution #1: Upgrade Undersized Piping
Identify worst sections (highest pressure drop). Replace with larger pipe.
Typical project:
- Replace 200 feet of 1" pipe with 2" pipe
- Cost: $2,000-$5,000 in materials and labor
- Pressure drop reduction: 15 PSI to 5 PSI (10 PSI improvement)
- Energy savings: 5% = $2,250/year (100 HP system)
- Payback: 1-2.5 years
Pro tip: Don't have to replace everything. Find the bottlenecks (main headers, high-flow sections) and upgrade those.
Solution #2: Convert to Ring Main (Loop) Layout
Instead of dead-end branches, create a closed loop. Air can flow in both directions to any point.
Advantages:
- Lower pressure drop (air takes shortest path)
- Redundancy (can isolate section without shutting down)
- Easy to expand (tap into loop anywhere)
Cost: $5,000-$20,000 depending on plant size
ROI: 2-4 years from energy savings plus reliability benefit
Solution #3: Actually Change Your Filters
Simple fix:
- Set up filter change schedule
- Train operators to check differential pressure
- Stock replacement elements
- Change when differential hits 5-10 PSI
Cost: $50-$200 per filter element
Benefit: Eliminate 5-15 PSI unnecessary pressure drop
Solution #4: Add Receivers Near High-Demand Areas
Large receiver near high-demand equipment (injection molding, packaging) buffers short-term demand peaks.
Benefit:
- Reduces pressure swings
- Allows you to run smaller piping to that area
- Compressor doesn't see the peaks (runs more steadily)
Cost: $2,000-$8,000 for receiver + installation
Payback: 1-3 years from improved efficiency and reduced piping costs
Real Example
Plant: Automotive parts manufacturing, 150 HP system
Problem: Making 125 PSI at compressor, far end getting 90 PSI (35 PSI drop!)
Investigation:
- Original 1-1/2" main header extended 400 feet over the years
- Now pushing 400 CFM through pipe sized for 150 CFM
- Multiple dirty filters (never changed in 2+ years)
- Dead-end layout
Solutions implemented:
- Replaced main header with 3" pipe: $8,000
- Created partial loop to new production area: $4,000
- Changed all filters: $600
- Set up filter change schedule: $0
Total cost: $12,600
Results:
- Pressure drop: 35 PSI → 8 PSI (27 PSI reduction!)
- Lowered compressor setpoint from 125 to 100 PSI
- Energy savings: 12.5% = $8,400/year
Payback: 18 months
Plus: More stable pressure, production quality improved, operators happy
Energy Waster #4: Inefficient Compressor Control (The Unload Waste)
If you're running an old fixed-speed load/unload compressor for variable demand, you're probably wasting 20-35% of your energy during part-load operation.
The Load/Unload Problem
How it works:
- Demand drops below compressor capacity
- Compressor unloads (stops compressing air)
- Motor keeps running at full speed
- Inlet valve closes
- Compressor makes zero air but still burns 15-35% of full power
The waste:
- You're paying for electricity to produce zero air
- Unload time wastes energy
- More unload time = more waste
How Bad Is It?
Example: 100 HP Compressor
- Full load power: 75 kW
- Unloaded power: 15-25 kW (20-35% of full load)
- Runs unloaded 40% of the time (common in batch manufacturing)
Calculation:
- Unloaded: 20 kW × 2,400 hrs/year = 48,000 kWh/year wasted
- Cost: $4,800/year at $0.10/kWh
Just thrown away. Producing zero air.
The Variable Speed Drive (VSD) Solution
How VSD works:
- Motor speed adjusts to match actual air demand
- Need 50% capacity? Motor runs at ~50% speed
- Need 75% capacity? Motor runs at ~75% speed
- Power consumption matches demand closely
Energy savings:
- At 50% load: VSD uses ~60% power, load/unload uses ~70-80% power
- At 75% load: VSD uses ~80% power, load/unload uses ~85-90% power
- Typical savings: 20-35% at part-load conditions
VSD Economics
Cost premium over fixed-speed:
- VSD premium: $10,000-$20,000 (for similar sized compressor)
- Or retrofit existing compressor: $8,000-$15,000
Energy savings (depends on load profile):
- High part-load operation (30-70% load): $8,000-$15,000/year
- Moderate part-load (70-90% load): $3,000-$8,000/year
- Constant full-load: $500-$2,000/year (minimal benefit)
Payback:
- High part-load: 1-2 years
- Moderate part-load: 2-4 years
- Constant full-load: 5-10 years (not worth it)
When VSD Makes Sense
Great fit:
- Variable demand (batch manufacturing, packaging lines)
- Compressor runs part-load more than 50% of time
- Single compressor serving variable demand
- You're replacing an aging fixed-speed unit anyway
Example applications:
- Packaging lines (run hard during production, idle during changeovers)
- Batch manufacturing
- Facilities with day/night demand variation
- Injection molding (cyclical demand)
Poor fit:
- Constant full-load operation (3-shift continuous production at steady rate)
- Multiple compressors where you've already optimized sequencing
- Very small compressors (under 20 HP - payback too long)
Alternative: Better Sequencing for Multiple Compressors
If you have multiple compressors, proper sequencing can achieve similar results to VSD:
Setup:
- 2× 75 HP fixed-speed compressors (base load)
- 1× 50 HP VSD compressor (trim)
How it works:
- Base compressors run full-load (most efficient)
- VSD trim handles variation (runs at part-load efficiently)
- Sequencer controller coordinates all units
Benefit: Base-load units run efficiently, VSD handles variation, overall system efficiency optimized
Cost: $5,000-$15,000 for sequencer + VSD trim compressor
→ Learn more: Multi-Compressor Control & Sequencing
Real Example
Plant: Electronics manufacturing, variable production schedule
Before:
- 100 HP fixed-speed compressor
- Runs unloaded 45% of time (nights, weekends, between batches)
- Annual energy: 450,000 kWh
- Cost: $45,000/year
Solution: Replaced with 100 HP VSD compressor
Cost: $55,000 (vs $40,000 for fixed-speed replacement)
Premium: $15,000
After:
- Annual energy: 315,000 kWh (30% reduction)
- Cost: $31,500/year
- Savings: $13,500/year
Payback: 1.1 years
Plus benefits:
- More stable pressure (±2 PSI vs ±10 PSI)
- Softer starts (less electrical demand peaks)
- Quieter operation
- Less wear from load/unload cycling
Bonus Waster: The Oversized Compressor Problem
This one deserves special mention because I see it all the time, and it creates multiple problems.
The Sales Pitch
Salesperson: "You're a serious operation, you need a rotary screw compressor. I recommend a 40 HP unit to make sure you have enough capacity."
Reality: Plant only needs 20-25 HP worth of air, and it's not running continuously—maybe 4-5 hours per day actual usage.
Why salespeople do this:
- Bigger compressor = higher commission
- "Better safe than sorry" sounds responsible
- Many don't understand the problems it causes
Why Oversized Screw Compressors Are a Problem
Rotary screw compressors are designed to RUN. They need operating hours to:
- Keep oil circulating and warm
- Expel moisture that condenses inside
- Keep seals lubricated
- Maintain proper temperatures
If your oversized compressor only runs 2-4 hours per day:
Problem #1: Moisture accumulates inside
- Oil stays cold, doesn't properly separate moisture
- Water condenses in oil reservoir
- Rust forms inside components
Problem #2: Oil problems
- Oil never reaches proper operating temperature
- Condensate emulsifies with oil (makes mayonnaise-looking gunk)
- Seals dry out from sitting idle
- Oil deteriorates from moisture contamination
Problem #3: Internal corrosion
- Components rust from moisture
- Air-end corrosion
- Valves stick
Problem #4: More problems downstream
- More moisture in air lines (cold oil doesn't separate well)
- Oil carryover issues
Real Horror Story
I tore down a 3-year-old 50 HP screw compressor that only had 1,200 hours on it (less than 1 hour per day average).
What I found:
- Inside was full of rust
- Oil was milky from water contamination
- Seals were dried out
- Air-end had corrosion
Owner thought he was being smart buying "plenty of capacity."
Cost him: $12,000 rebuild on a nearly-new compressor.
The Right Approach
Size for actual demand, not theoretical maximum:
- Measure actual air consumption
- Size compressor to run at least 50-60% loaded
- If usage is intermittent, consider piston compressor instead
- Or get smaller screw that runs more hours
- Or add large receiver to buffer demand (lets smaller compressor run longer cycles)
When bigger makes sense:
- You're planning expansion (but be realistic)
- Demand is truly variable and you need VSD anyway
- Multiple shifts with growing usage
When it doesn't:
- Single-shift operation with predictable demand
- Intermittent usage (a few hours per day)
- "Just in case" thinking with no real plans
Total Potential Savings
Let's add it all up for a typical 100 HP system running 6,000 hours/year at $0.10/kWh:
Annual energy cost: $45,000
Waste #1: Leaks (25% loss)
- Wasted: $11,250/year
- Fix cost: $3,000-$6,000
- Payback: 3-6 months
Waste #2: Excessive Pressure (20 PSI over target)
- Wasted: $4,500/year
- Fix cost: $0 (turn dial) or $500-$2,000 (point-of-use boosters)
- Payback: Immediate to 4 months
Waste #3: Pressure Drop (15 PSI compensated)
- Wasted: $3,375/year
- Fix cost: $5,000-$15,000 (piping upgrades)
- Payback: 1.5-4 years
Waste #4: Poor Control (40% unload time)
- Wasted: $4,800/year
- Fix cost: $10,000-$20,000 (VSD)
- Payback: 2-4 years
Total recoverable waste: $24,000/year (53% of energy cost!)
Total investment to fix: $18,000-$43,000
Payback: 9 months to 2 years
20-year net savings: $480,000 - $43,000 = $437,000
Your Action Plan
Phase 1: Find the Low-Hanging Fruit (Month 1)
Week 1: Assessment
- Calculate baseline energy costs
- Do shutdown test to measure leak rate
- Measure system pressure (compressor vs far points)
- Check compressor load/unload patterns
Weeks 2-4: Quick Wins
- Fix obvious big leaks (fast payback)
- Lower system pressure if over-pressurized (free money)
- Clean/replace dirty filters (immediate benefit)
- Set up auto-shutoff if not running 24/7 (easy savings)
Expected savings: 5-15% = $2,250-$6,750/year
Cost: Under $2,000 typically
Payback: 2-6 months
Phase 2: Major Improvements (Months 2-6)
Systematic leak program:
- Buy or rent ultrasonic detector
- Complete facility audit
- Tag and prioritize all leaks
- Fix leaks systematically
- Set up quarterly re-audit schedule
Pressure drop analysis:
- Identify bottleneck piping
- Upgrade critical sections
- Consider ring main conversion
- Add strategic receivers
Control system upgrade:
- VSD retrofit or replacement (if justified by load profile)
- Multi-compressor sequencer (if multiple units)
Expected additional savings: 15-25% = $6,750-$11,250/year
Cost: $10,000-$40,000
Payback: 1-4 years
Phase 3: Keep It Optimized (Ongoing)
- Quarterly leak audits (they always come back)
- Annual system performance review
- Monitor energy consumption (set up tracking)
- Train operators on best practices
- Make compressed air efficiency a KPI
Recommended Resources
System Optimization:
Compressed Air System Optimization - Complete optimization guide
For Large/Complex Systems:
Multi-Compressor Control & Sequencing - How to coordinate multiple compressors efficiently
Heat Recovery Systems - For 100+ HP systems, another $50,000-$200,000/year opportunity
Equipment Selection:
Rotary Screw Air Compressor Buying Guide - Don't buy the wrong size!
Training:
Industrial Compressed Air Systems Course - Comprehensive training on system design, operation, and optimization
Tools:
Compressed Air System Simulator - Model your system and test optimizations before spending money
Bottom Line
THE BIG 4 energy wasters—leaks, excessive pressure, pressure drop, and poor control—waste 20-40% of compressed air energy in most plants.
That's $9,000-$18,000 per year on a typical 100 HP system.
The good news? These are systematic, fixable problems with fast paybacks:
- Leak detection and repair: 3-12 months
- Pressure optimization: Immediate to 6 months
- Pressure drop fixes: 1-4 years
- Control upgrades: 1.5-4 years
Unlike other energy efficiency projects, compressed air optimization often pays for itself in under a year.
You're already paying for the compressed air. Now stop wasting it.
Ready to start? Read the complete optimization guide or ask specific questions in the forum.