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Are Compressed Air Audits the Key to Lowering Your Energy Costs?

mars 18, 2025
Are Compressed Air Audits the Key to Lowering Your Energy Costs?
Manufacturing facilities spend nearly 40% of their energy costs on compressed air, having an efficient system is key to keeping expenses down and profits up. Unfortunately, not all systems operate in the most efficient manner possible, and we see it every day – compressors not appropriately sized, outdated technology, air leaks, pressure drops – the list can go on and on. 
 
The U.S. Department of Energy estimates that more than half of industrial air compressors run inefficiently, wasting $3.2 billion in energy each year. However, manufacturers in this study that invested in efficiency improvements achieved annual energy savings of over 15%, with their upgrades paying for themselves in less than two years.

How Can a Compressed Air Audit Reveal the Health of Your System?

A compressed air audit is the first step in identifying inefficiencies that may be increasing energy costs and reducing system performance. Conducting an audit provides valuable insights into leaks, pressure drops, and equipment performance, allowing businesses to make informed decisions about system improvements. 
There are three primary levels of compressed air audits, each offering different levels of detail:
  • Walk-Through Evaluation
  • System Assessment
  • Full System Audit

Walk-through Evaluation

A walk-through evaluation provides a high-level overview of the plant’s compressed air system and typically takes between half a day to two days. This assessment includes: 
  • Checking for air leaks, pressure drops, and compressor sizing issues
  • Mapping out the entire compressed air distribution system
  • Providing a detailed report with findings and recommended solutions
 
This quick evaluation is ideal for identifying obvious inefficiencies and determining whether a more in-depth assessment is necessary.

System Assessment

A system assessment offers a more thorough analysis by incorporating data collection and system dynamics monitoring in addition to a standard walk-through. The compressed air system mapping will also feature pressure and demand profiles. 
 
The report from a system assessment will not only pinpoint areas of energy waste but also offer targeted solutions to improve efficiency.

Full System Audit

The system audit is the most comprehensive review and takes around three to ten days with little to no impact on current running procedures. Full compressed air system audits include: 
 
  • Energy usage data logging – logs the energy the air compressors are consuming.
  • Air measurement – identifies a factory’s true compressed air demand and operating schedule.
  • Air leak detection & control – identify how much air is being lost due to leaks.
  • Air quality – measures the number of particulates in the air system such as water and oil.
  • Maintenance review – assesses the effectiveness of the current maintenance plan.
  • Monitoring & control program – makes recommendations to maintain optimum efficiency.
 
 Explore walk-through evaluations, system assessments, and full audits today at Compressed Air Challenge.

The Benefits of an Air Audit for Manufacturers

Compressed air audits deliver measurable benefits across various industries, including food and beverage, automotive, electronics, plastics, and power generation.
By identifying inefficiencies, manufacturers can experience: 
  • Lower operating costs – Optimized systems require less energy to maintain performance
  • Increased reliability – Preventative maintenance reduces unexpected downtime
  • Improved system efficiency – Eliminating leaks and pressure drops enhances output and reduces energy consumption.
 
For example, many plants operate at higher pressures than necessary due to leaks, pressure drops, or poor piping design. If a facility requires 100 psi but compensates by producing 120 psi, it wastes 20 psi—resulting in excessive energy consumption and unnecessary costs. A compressed air audit can help uncover and resolve these inefficiencies.

Conducting a Pre-Audit Analysis with AirCompare

Before scheduling an air audit, we encourage you to run an AirCompare report to gain insight into how your compressor technology impacts energy costs. After reviewing your results, you can request a more detailed, site-specific AirCompare report by contacting us today. 
 
This report not only provides a thorough cost analysis of your current compressed air system but also identifies opportunities to reduce your carbon footprint! 
RUN AIRCOMPARE

Improve Compressed Air Efficiency with a System Audit

Connect with our team to explore how a compressed air system audit can help identify energy inefficiencies, uncover opportunities to reduce operating costs, and optimize overall compressor performance.

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