Stoke Depot Opening Times: 07.30am – 5.00pm Mon to Fri | Shrewsbury Depot Opening Times: 08.00am – 5.00pm Mon to Fri
Stoke Depot Opening Times: 07.30am – 5.00pm Mon to Fri | Shrewsbury Depot Opening Times: 08.00am – 5.00pm Mon to Fri
J Ll Leach carries out comprehensive energy audit for air compressors services from our Stoke, Birmingham and Shrewsbury branches.
Your compressed air system likely accounts for about 10% of your electricity bill, often making it one of the largest single utility expenses for a facility. That makes it worth checking whether you’re getting value for money and managing your operating costs through optimised system efficiency.
J Ll Leach has been maintaining compressed air systems across the Midlands since 1936. We work from depots in Stoke-on-Trent, Birmingham and Shrewsbury.
Most compressed air systems lose compressor efficiency over time. We regularly encounter issues that increase running costs.
Air leaks are the biggest culprit. Individual leaks might be small, but they add up. We’ve measured systems losing 30% of their compressed air through leaks. A single 3mm simple leak can cost over £700 per year. Leaks reduce pressure, which forces your compressor to work harder and can create “artificial demand,” where equipment uses more air than it needs simply because the pressure is too high.
Equipment wear also takes its toll. Air compressors, dryers and filters all drift from their original settings. A slightly worn valve seat here, calibration that’s shifted there. The equipment still works, but not as well as it should.
System changes create problems, too. Businesses grow and change. Pipework is extended, new connections are added, and production layouts are altered. What started as an efficient system can end up with unnecessary bends, old or bad piping, and longer pipe runs than needed.
We measure rather than guess. Our comprehensive air audits utilise specialised data-logging equipment to track your system’s performance and efficiency over a minimum of one week.
We begin with a comprehensive inventory and site survey of all air compressors, compressed air dryers, filters, and receivers in your existing system. Then we conduct a visual inspection of the pipework and connections.
Our engineers install temporary data loggers at various points. These record power use, pressure levels, airflow, and air quality over several days. This reveals compressed air usage patterns, captures the true air demand across different shifts, and identifies areas where compressor energy is being wasted.
We utilise ultrasonic leak detection equipment to find and quantify leaks. This survey on your compressed air system picks up high-frequency sounds that compressed air makes when escaping through small holes – leaks you can’t hear above normal factory noise.
After a week of monitoring, we analyse the data and provide a detailed report with specific recommendations and estimated costs. This comprehensive energy audit for air compressors pdf report is delivered to you, outlining clear steps for improvement.
Common findings include a full list of leak locations throughout the compressed air system, incorrect system pressure settings, and blocked filters, which force compressors to work harder. We often identify pipework that creates unnecessary pressure drops and opportunities for improved load balancing, particularly when you have multiple compressors. Our audit report identifies all areas of improvement and quantifies the potential energy savings.
Reducing pressure by one bar typically results in a 7% reduction in energy costs. That’s a simple change that can save hundreds of pounds annually on a typical system.
Equipment upgrades may include new filters, installing a variable-speed drive (VSD) for improved load matching, or implementing heat recovery systems to capture waste heat. We also examine pipework improvements using modern, corrosion-free aluminium systems, such as AIRnet.
A professional compressed air audit is a strategic investment that delivers a clear Return on Investment (ROI). The initial purchase price of a compressor is only a fraction of its total Life Cycle Cost (LCC), with energy consumption often accounting for over 70% of the total cost. Our detailed report provides the financial justification you need for system upgrades.
Many clients ask about the energy audit for air compressors cost; however, the savings identified usually outweigh the fee. We identify the potential energy savings and calculate the payback period for recommendations like leak repairs, which can often pay for themselves in months, or VSD compressor installations, helping you reduce compressor energy costs and improve your bottom line.
Understanding your baseline is key. To calculate the energy consumption of an air compressor manually, you need to know the compressor’s motor power rating (in kW), the total running hours, and the percentage of time it runs fully loaded versus unloaded. However, manual calculations are often estimates. Our air audits use precision data logging to measure the exact power draw over time, providing a far more accurate figure than simple theoretical calculations.
We conduct our assessments in accordance with ISO 11011:2013, the international standard for compressed air energy efficiency assessments. This rigorous, data-led approach ensures our findings are accurate, verifiable, and comprehensive. For large UK undertakings, our audit compressed air report provides the technical documentation and energy-saving opportunities required for compliance with the Energy Savings Opportunity Scheme (ESOS). This elevates our service from a simple check-up to a key component of your corporate energy strategy and helps reduce CO2 emissions.
Manufacturing sites in Stoke often have systems that have grown over decades. Original air compressors may be oversized for current needs, or pipework routes may be inefficient due to factory layout changes.
Food processors in the Birmingham area typically require consistent air quality and pressure. For any business in the Midlands seeking an energy audit for air compressors in Birmingham, Stoke, or Shrewsbury, we often find that multiple small leaks are affecting both, even though individual tools still seem to work normally.
Workshop compressors used intermittently have different problems than production-line air systems that run constantly. Load patterns matter when identifying energy waste.
Rising electricity bills without obvious reasons often point to compressed air system problems. If you’ve added new equipment, changed shift patterns, or extended your factory, your existing compressed air system might need rebalancing.
Systems over five years old often benefit from an audit, especially if maintenance has been minimal or reactive rather than planned.
As Atlas Copco Premier Distributors, we utilise professional monitoring equipment, such as AIRScan, and adhere to industry standards. Our audit may also recommend integrating smart monitoring systems like SMARTLINK to maintain long-term energy savings. Our engineers understand the practical challenges of keeping systems running in working factories.
We schedule monitoring to minimise disruptions to production. Data loggers run continuously while you work normally. Physical inspections can be arranged for quiet periods if needed.
Most air audits identify improvements that pay for themselves within months through reduced electricity costs. This is the first step to optimise your system for maximum operational efficiency.
Ring our nearest depot to discuss your system. We can start monitoring within a week of your call, depending on equipment availability and your schedule.
Yes. Under the Pressure Systems Safety Regulations 2000 (PSSR), a Written Scheme of Examination is a legal requirement for most compressed air systems. While our energy audit focuses on efficiency and cost reduction, we can also advise on your statutory inspection obligations to ensure your system is safe and compliant.
Most industrial operations benefit from annual leak detection surveys. If you notice performance changes or make significant alterations to your system, a full energy audit for air compressors is worth checking sooner.
Data logging runs for at least a week to capture your standard operating patterns. Our engineers typically spend 1-2 days on site setting up equipment and conducting inspections.
No. We design monitoring solutions to work seamlessly with your normal operations. Most equipment can be installed during brief stops or shift changes.
We audit and service all makes of compressed air equipment. Our monitoring techniques work regardless of the manufacturer.
An energy audit of an air compressor is a multi-step process. It begins with a site survey and inventory of your existing system. We then install data-logging equipment for at least one week to monitor your air demand, compressor energy consumption, and system pressure. This is combined with an ultrasonic leak detection survey and an air quality analysis. Finally, we provide a detailed report that quantifies all energy waste and provides clear recommendations for cost savings.