Compressed air runs pneumatic tools and machines in factories. Despite being vital, many systems waste energy. Leaks, pressure drops, and old equipment can lose 30% of the air produced, pushing up electricity bills.
A compressed air audit examines your entire system. Engineers measure air demand at different points and monitor pressure levels throughout the day. They attach data loggers to key components to track performance over several shifts.
Most audits happen because of high energy costs or unreliable equipment. The assessment finds practical improvements – fixing leaky pipes in the workshop, adjusting settings on specific machines, or changing maintenance schedules. Benefits include lower running costs and fewer breakdowns.
The process typically takes two days. On the first day, engineers install measuring equipment and inspect the compressor room. On the second day, they analyse the collected data and discuss findings with maintenance staff. Production can continue as usual during most of the assessment.
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
Compressed air audits provide practical benefits. These examples show typical outcomes from recent UK projects.
Kettering Cement Plant Saves £22,000
Cement works in Northamptonshire faced rising electricity costs due to their ageing compressors. The audit found they were running at 8.2 bar when most equipment needed only 6.5 bar. Leaks in the mixing area wasted 18% of output.
After fitting variable speed drive (VSD) compressors and fixing 23 identified leaks, their quarterly electricity bill dropped by £5,500. The maintenance supervisor now checks for leaks monthly using an ultrasonic detector borrowed from their sister plant in Sheffield.
Birmingham Fabrication Firm Cuts Usage in Half
A metal fabricator operating from a 1970s industrial unit discovered their three fixed-speed compressors ran continuously, even during tea breaks and shift changes. The audit used data loggers on each machine for a week in February.
Results showed they needed only 60% of their installed capacity. They replaced two units with a single VSD model and programmed automatic shutdown during the 30-minute lunch break. Their annual saving reached £8,400, with a 3.2-year payback period.
Engineering Workshop Reduces Downtime
A Swindon engineering firm with 12 staff members had problems with inconsistent pressure. Tools often stopped working mid-afternoon, particularly on Thursdays when production peaked.
The audit revealed dust-clogged filters and 32 mm pipes where 50 mm was needed. After upgrading the distribution system and adding a cyclone separator, pressure remained steady at 6 bar. Machine stoppages fell from three weekly to one monthly, saving 14 hours of lost production time.
All three companies implemented recommendations within their scheduled maintenance periods, avoiding additional downtime.
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.
FAQ
What happens during a compressed air audit?
Our engineer spends a day at your site, measuring your system’s performance. They check air pressure at different points in the factory, look for leaks using an ultrasonic detector, and install data loggers on the compressors. We typically record information for 7–10 days, measuring pressure, flow, and power consumption every 30 seconds. This shows us how the system copes during different production runs.
The final report includes graphs of air usage, any leaks found (with photos), and specific recommendations. Most customers receive their report within two weeks of the site visit.
How does an audit reduce energy costs?
Most factories waste air through leaks, poor pipework or incorrect pressure settings. Our audits typically find 15–20 leaks per site, often around hose connections and cylinder fittings.
Last month, we found a Manchester textiles firm was running their compressors at 7.5 bar when their looms needed only 6 bar. Lowering the pressure saved them £4,700 yearly on electricity.
Other common issues include compressors running during breaks, undersized receivers causing rapid cycling, and departments using different pressure requirements on the same network.
Is an audit worthwhile for a small workshop?
Even small systems benefit from checking. A five-person joinery shop in Leeds found they were wasting £1,200 yearly on air leaks. Their single 11 kW compressor cycled all weekend to maintain pressure due to a damaged drain valve.
We offer half-day assessments for sites with one or two compressors. These focus on checking basic efficiency, finding obvious leaks, and ensuring that filters and separators work properly. The service costs £350 plus VAT and takes about four hours to complete.