Compressed Air Leak Detection

Compressed air systems are essential for running machinery and other production operations, in a multitude of industries. Ironically, the cost and electrical power required to own and operate a compressed air system can be highly expensive, and most users consciously recognize this. However, despite this knowledge, they allow air leaks to quietly eat away at the companies’ bottom line profits, while trying to cut expenditure in other critical areas of their maintenance operation to balance budgets.

Does this sound familiar?

Industrial manufacturers and other production or service establishments disregarded compressed air leaks in their processes for many years. However, the industry standard has changed drastically, and now, not only does conserving this resource help save money, but it can also boost machinery performance while enhancing product quality. Compressed air is one of the most expensive energy sources in an industrial facility, and according to the Department of Energy (DOE), on average, compressed air systems that are not regularly maintained after installation could be losing 20 to 30% of compressed air in leaks.

In short, air leaks might be costing your business considerable amounts of money through unnecessary electrical costs, created by “easy to combat” compressed air leaks.

If you choose to ignore the negative effects that air leaks may have on your yearly energy costs, it’s important to note that leaks will still reduce operating efficiency, and lead to lost productivity because of the system's unavoidable decline in air pressure. This might lead to shorter equipment service lifespans and less effective use of processes, air tools, spray paint finishes, cylinders, valves, and “blow offs” which use compressed air.

Unfortunately, leak identification and repair are never one-time events. The compressed air system will likely require more maintenance as it matures, or changes over time. Leak detection and repairs must be viewed as a continuous program if you want long-term outcomes. The simplest method to make sure leak detection is remembered is to create a program for continuous improvement. You might want to talk to your compressed air service provider about incorporating leak detection into your preventative maintenance schedule as part of this plan. Energy savings from a continuous leak detection audit and repair program will quickly provide a rapid ROI. In addition, you will benefit from improved manufacturing equipment performance and less downtime.