In many factories, 20-30% of compressed air is lost to leaks. That's like running your compressor one day a week just to feed the leaks.

What you'll see

The compressor runs loaded more than it should. Energy bills are high. The machine rarely or never reaches unload. When production stops (nights, weekends), the compressor still cycles on and off -- air is going somewhere even with no demand. Walk the system in a quiet moment and you'll hear it: hissing from fittings, couplings, regulators, and old equipment everywhere.
Before you assume this is the problem

See all causes of high energy use →

How to diagnose

  1. Night/weekend test

    When no one is using air, observe the compressor. If it keeps cycling (loading and unloading), air is leaking somewhere. Time how long it stays loaded vs unloaded. A leak-free system should hold pressure indefinitely with zero demand.

    Result: Compressor cycles with zero demand = leaks.

  2. Walk the system and listen

    In a quiet shop, walk every meter of piping, every connection, every piece of equipment. Mark every leak. Use soapy water on suspect joints to visualize small leaks.

    Result: Leaks found = fix them.

How to fix it

  1. Fix all leaks systematically

    Start with the biggest ones. Replace worn quick-connect couplings, tighten fittings, replace damaged hoses, cap unused air points. Make leak detection a regular maintenance activity, not a one-time event. Leaks come back.

Common mistakes

Don't raise the compressor pressure to compensate. Higher pressure means more airflow through each leak (leak rate increases with pressure), higher energy use, and more stress on the system.

Parts & tools

Replacement fittings, hoses, couplings. Soapy water or ultrasonic leak detector.

Review safety precautions before starting →

This issue can also cause

  • Low Pressure / Can't Reach Setpoint Compressor runs and loads, but pressure stays below setpoint: often caused by leaks, restrictions, or capacity...
  • Pressure Drop Significant pressure loss between the compressor discharge and point of use, causing tools to underperform des...