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
Track exactly how your compressed air system is performing with real-time flow monitoring that cuts waste, prevents downtime and breakdowns, and saves money. This data-driven approach allows for true compressed air consumption monitoring, giving you control over your energy costs and system health.
J Ll Leach has been working with compressed air systems since 1936. From our depots in Stoke-on-Trent, Birmingham and Shrewsbury, we see businesses across the Midlands struggling with the same problems – systems that use more energy than they should and break down without warning. Many companies are unaware of their true compressed air consumption or the cost of leaks.
Flow monitoring shows you what’s happening with your compressed air. The data helps you spot problems early and keep running costs down. It provides the real-time data and critical data points needed to improve efficiency.
Compressed air systems work hard. Without compressed air monitoring, you won’t know if yours is wasting energy or heading for trouble. This inefficiency can lead to high energy costs and unexpected downtime.
Common problems include:
Use thermal mass or ultrasonic technology to measure airflow and air consumption. They’re accurate to within 1-2% and can detect leaks before you hear them. While thermal mass meters are excellent for dry air, they are sensitive to moisture. We will assess your air quality and pipework to recommend the right technology for the job, which may also include Vortex or Differential Pressure (DP) meters.
Track system pressure at different points. Falling pressure often indicates leaks or blockages. This helps manage system fluctuation.
Measure exactly how much electricity your compressor uses. This helps calculate the real cost of compressed air and benchmark your energy efficiency.
Monitor the compressor and air temperatures. Overheating usually means maintenance is needed.
Measure moisture in the air supply. Critical for applications where water contamination causes problems.
For a complete picture, we often start with a comprehensive air audit, sometimes called an AIRScan. We use temporary data loggers to record your system’s performance over several days. This helps us establish a baseline and identify patterns, providing the foundation for a permanent air monitoring system and a robust energy management system.
Energy typically accounts for 70% of compressed air costs. A 5mm hole in your airline costs about £400 per year to run. Most businesses have several leaks they are unaware of.
Monitoring helps by:
We’ve installed compressed air monitoring systems that pay for themselves within 12 months through energy savings alone.
As Atlas Copco Premier Distributors, we install SMARTLINK cloud-based systems that connect your compressor to our service team. The system continuously sends compressor data and alerts us to any problems, often sending a notification directly to your mobile app.
SMARTLINK monitors:
You get access to the same data through a web dashboard. The system is compatible with most smartphones and tablets. This gives you 24/7 access to your air system’s critical data points and optimal performance.
Most monitoring equipment can be fitted during regular operation. Ultrasonic compressed air flow meters clamp onto existing pipes without cutting or welding. Installation typically takes 2-4 hours, depending on the system size. We ensure proper installation, including adhering to requirements for straight pipe runs, to guarantee measurement accuracy.
We work around your production schedule. Many installations happen during planned maintenance or at weekends.
Our engineer visits to assess your system and recommend suitable monitoring points. We then:
Documentation includes operating instructions and maintenance schedules.
Our monitoring systems work across different sectors:
Automotive components, textiles, general engineering
Breweries, bakeries, packaging operations
Pottery manufacturers around Stoke-on-Trent
Hospitals and medical device manufacturers
Companies requiring validated air quality
Each industry has different air quality requirements. We configure monitoring systems accordingly, from general manufacturing to validated pharmaceutical air quality. Our Birmingham and Midlands teams also have experience with specialised air sampling systems for critical applications.
Monitoring equipment needs regular calibration to stay accurate. We check sensors every 12 months and recalibrate as needed. This ensures your data remains traceable and reliable, which is essential for compliance and auditing (such as ISO 11011).
Software updates happen automatically through the network connection. Technical support is available during normal business hours.
Emergency call-out is available for system breakdowns. Our engineers carry standard spare parts and can often fix problems the same day.
Contact us to arrange a site visit. Our engineer will assess your compressed air system and recommend monitoring points. We’ll explain what compressed air monitoring equipment is needed and provide a fixed-price quotation.
Installation can usually be scheduled within 2-3 weeks of the order.
Modern thermal mass air flow meters are accurate to within 1-2% of the reading. They’re calibrated in our workshop before installation and checked annually to maintain accuracy.
Yes. An air monitoring system is compatible with any compressed air system, regardless of age. Sensors connect to the pipework and don’t require modifications to the compressor itself.
Your compressor continues to operate normally. Monitoring systems are separate from compressor controls and don’t affect operation. We carry spare parts for quick repairs.
A typical installation takes half a day. Large systems with multiple monitoring points might take a full day. We work around your production schedule to minimise disruption.
Specific Power is the key metric for measuring compressor efficiency. It’s the ratio of energy used (kW) to the compressed air output (often in m³/min). A lower Specific Power value means higher efficiency. Our compressed air monitoring helps you measure and improve this crucial benchmark.
Energy audits and reporting are now a legal requirement for many UK businesses under schemes like the Energy Savings Opportunity Scheme (ESOS) and Streamlined Energy & Carbon Reporting (SECR). A permanent flow monitoring system provides the accurate, verifiable data on your compressed air energy consumption required for these reports, ensuring you are compliant.
Downtime monitoring is a key feature of our systems. Instead of just waiting for a breakdown, the system’s real-time data analysis can spot small deviations in temperature, pressure, or flow that signal a component is failing. This allows for predictive maintenance, preventing unplanned downtime before it stops your production.