Inefficiencies can lead to significant losses in large-scale operations, especially when it comes to poorly maintained or energy-inefficient equipment. Often overwhelmed with day-to-day responsibilities, operations managers need a clear starting point to evaluate and enhance their current air compressor systems. This is where a compressed air audit becomes invaluable.
A compressed air audit offers a comprehensive review of your entire compressed air system, pinpointing areas for improvement to reduce waste, boost energy efficiency, and potentially enhance productivity. By identifying areas for optimisation, an audit can significantly extend the lifespan of equipment, reduce operational costs, and enhance overall sustainability. An audit can increase reliability and reduce downtime by identifying necessary changes.
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Understanding Compressed Air Audits
Air audit services are intended to improve the overall efficiency of your system. A thorough audit evaluates performance metrics such as pressure, flow rate, energy consumption, and air quality, offering data-driven solutions for improvements. The benefits of a compressed air audit should surpass the expense by a considerable margin.
Air audits are important because they entail a systematic review of your entire air compressor system, including air boosters, and other equipment. Inefficiencies are identified, along with recommended steps for improvement.
In some cases, your operations manager or other personnel can handle these internally. In other cases, an air specialist like J LL Leach is well-positioned to deliver value-added solutions.
A comprehensive leak detection review can find numerous air leaks. This is not uncommon, especially with older air compressor systems. Financial losses resulting from air pressure leaks are considerable. These include producing extra air to mitigate the leakage losses, the resulting extra wear on equipment, and additional energy usage. Studies show that air leaks can account for up to 30% of compressed air system losses, making leak detection critical for efficiency improvement.
Modern audits often use advanced tools like flow meters, thermal imaging, and energy monitoring software (e.g. Atlas Copco’s SMARTLINK) to provide precise data for optimisation.
Overworked air systems affect system reliability. Industrial facilities will not necessarily connect air leakage with declining system performance. However, a whole system review isolates less obvious causes through a detailed analysis of the data. Our team then identifies areas for improvement and makes recommendations to boost performance and efficiency.
A full review may include, but is not limited to:
- Conducting a complete air audit to obtain a clear picture.
- System analysis audit to identify weak points or gaps, including controls and overall design.
- Energy vs production: looks at how much energy (kilowatts) is used to produce a standard quantity of compressed air (100 cubic feet per minute).
- Measurement of air settings relative to current output.
- Total airflow expectation vs current reality.
- Air leak detection throughout the entire compressor system.
- Analysis of air quality and whether it is clean enough for your requirements (present and future). If not, what filtration or other recommendations are advisable?
- Distribution systems analysis, especially the piping structure, includes looking for pipes with rust and scale.

Key Benefits of Conducting Compressed Air Audits
There are many meaningful benefits to arranging a compressed air audit of your air systems.
Here are a few of them:
Energy Efficiency: Compressed air systems are energy-intensive, so any efficiency improvements are highly worthwhile. For instance, upgrading to energy-efficient compressors, such as variable speed drive (VSD) models, can yield up to 50% savings depending on operational patterns. Equipment updates are recommended where significant efficiencies are not possible with existing equipment.
Reducing Expenditures: Reviews focus on reducing costs without affecting air production. This includes stopping air leakage losses, fixing pipe distribution issues, and reconfiguring controls to maximise performance. Companies often see a return on investment (ROI) from an air audit in under two years by addressing inefficiencies.
System Reliability: Air audits identify early indicators of equipment failure. Pre-emptive parts replacement avoids costlier repairs and downtime. For example, addressing pressure drops caused by undersized piping or clogged filters enhances performance and reliability.
Environmental Considerations: Better energy efficiencies result in reduced carbon emissions. Complying with ISO 14001 environmental management standards is often an additional benefit, particularly for organisations in regulated industries.
Contact us to discuss air audit benefits and what J Ll Leach can offer you.
Case Studies and Real-World Examples
Below are a couple of examples of successful air audits:
A sizable cement manufacturer was considering upgrading its air compressors. A compressed air audit highlighted the benefits of moving away from their ageing compressors to newer variable-speed drive compressors. Rather than being fixed at a single speed, variable-speed drive compressors are built to allow for quick speed adjustments to accommodate changing air production requirements.
The air audit and subsequent upgrades removed over 120 tons of future emissions and reduced their energy bill by over £22,000 a year.
In another successful air audit, a fabrication company requested an iiTrak audit analysis – this is an audit carried out using Atlas Copco iiTrak software and monitoring equipment to establish energy usage over a predetermined time. This confirmed that their CNC equipment would benefit by replacing their existing air compressors with new Atlas Copco variable speed drive machines.
When completed, they realised over 50% energy savings with cost reductions of over £8,400 each year.
How to Prepare for a Compressed Air Audit
Here are some steps to take in preparation for a compressed air audit:
Clean the area: review the area to ensure it is clear of debris. Check that it is as accessible as possible. Remove any objects that do not need to be there.
Pro Tip: modern audits often involve remote monitoring tools that minimise disruption to ongoing operations while collecting detailed performance data.
Ensure access: verify that all components and parts within the system are accessible for review.
Locate all documentation: collate all air system documentation for review. This includes product manuals, system procedures, and other company information including your current electricity rates so that the analysis can be carried out.
Prepare site approval: complete any security approvals or other necessary actions ahead of time. Assign a member of staff responsible for the audit team to meet them upon arrival and stay with them.
Make staff aware: let employees know that there may be limited disruption to normal activities during the air audit.
Pitfalls to Avoid
Do not overlook problematic, difficult-to-access system areas where air leaks are possible. Clear access to them for review – this is helpful but not essential as our equipment allows analysis from a distance without having to be in close proximity to the leak.
All air system equipment needs periodic auditing!
Conclusion
A compressed air audit is essential to optimise equipment performance and minimise operational costs. By identifying inefficiencies, audits improve system reliability and enhance energy efficiency and environmental sustainability. Regular audits ensure compliance with industry standards, maintain competitiveness and reduce waste.
Ensure your equipment helps you to stay competitive. Contact us today to learn how we can help you.