A Step-by-Step Guide to Compressed Air Audits for Tennessee Businesses
Compressed air is a vital component in the daily operations of manufacturing plants, food processors, machine shops, and medical facilities across Tennessee. But without proper oversight, compressed air systems often become a major source of wasted energy and hidden expenses. That’s where a compressed air audit comes in — it’s the most effective way to assess system performance, detect inefficiencies, and uncover cost-saving opportunities.
If you’re considering an audit but aren’t sure what to expect, this guide walks you through every stage of the process. You’ll understand how the audit works, what data is collected, how problems are diagnosed, and — most importantly — how to turn the results into actionable improvements.
Whether you operate in Nashville, Knoxville, Chattanooga, or anywhere in Tennessee, this guide from Industrial Air Services will help you take control of your compressed air system and your energy budget.
Why Compressed Air Audits Matter
Compressed air systems are notorious for being energy-intensive. It’s estimated that only 10–15% of the energy used to compress air is actually used for productive work. The rest is lost through leaks, poor controls, incorrect sizing, and inefficient practices.
An audit can:
Identify and quantify these losses
Uncover equipment or installation issues
Improve system reliability and uptime
Reduce energy bills by 20–50%
Extend the life of your compressors and accessories
Step 1: Initial Consultation and System Review
The process begins with an on-site visit by an Industrial Air Services technician to evaluate your current system and discuss your facility’s goals.
During this visit, we’ll:
Walk through the plant and review equipment layout
Examine compressor makes, models, and run times
Discuss any known problems (e.g., pressure drops, overheating)
Review air demand trends and shift schedules
Establish performance benchmarks and energy targets
This step ensures the audit is customized to your specific operation — whether you’re producing automotive components in Murfreesboro or bottling beverages in Chattanooga.
Step 2: Data Logging and Monitoring
Next, we install temporary data loggers and monitoring devices to track your system’s performance under real operating conditions. This phase typically lasts 7 to 14 days.
Metrics We Track:
Air flow (SCFM)
Pressure (psi) across key points
Power consumption (kW) of each compressor
Compressor load/unload times
Ambient temperature and humidity
Peak and off-peak demand levels
These readings give us a real-time picture of how your compressed air system functions across different production cycles, shifts, and equipment loads.
Step 3: Leak Detection and Mapping
Compressed air leaks are the #1 source of energy waste in most facilities — often accounting for 20–40% of air loss. Using ultrasonic leak detection, our technicians walk the entire plant during quiet hours (or weekends) to locate and tag leaks.
We check:
Pipe joints, elbows, and fittings
Quick-connect couplers and hoses
Valves and regulators
Air-using tools and machinery
Condensate drains and filters
Each leak is marked, photographed, logged, and prioritized based on severity and cost impact.
Step 4: Data Analysis and System Diagnostics
Once we’ve collected performance data and leak information, we analyze it using industry-standard software and in-house engineering expertise.
Our analysis identifies:
Leak volume and associated energy cost
Compressor efficiency (kW/100 cfm)
Pressure drops across filters or piping
Idle run time and wasted load hours
Inappropriate uses of compressed air (e.g., cooling electronics, cleaning floors)
Sizing mismatches or oversupplied pressure
The result is a detailed snapshot of how much compressed air is being wasted and where improvements can be made.
Step 5: Recommendations and ROI Calculations
Armed with real data, we create a report that includes clear, actionable recommendations — each with estimated implementation costs, energy savings, and ROI.
Common Recommendations:
Repairing specific leaks (with cost/benefit breakdown)
Installing pressure regulators or zero-loss drains
Lowering system pressure without affecting performance
Retrofitting existing compressors with VFDs
Replacing oversized compressors
Installing storage tanks or smart controls
Eliminating non-essential air usage
Many clients are surprised to find payback periods of less than 12 months, especially when TVA incentives are available.
Step 6: Implementation Support
Industrial Air Services doesn’t just hand you a report and walk away. We offer full support to help you implement audit recommendations and maximize your return on investment.
Services Include:
Leak repair and component replacement
Compressor upgrades and retrofits
Piping modifications
Control system integration
Ongoing monitoring setup
Preventive maintenance plans
We also help coordinate TVA EnergyRight® rebate applications, where available, to offset project costs.
Step 7: Follow-Up Monitoring and Long-Term Support
After improvements are made, we conduct a post-implementation review to verify that energy savings and performance goals have been met. We also offer continuous monitoring options to ensure your system stays optimized over time.
Who Should Get a Compressed Air Audit?
You should consider an audit if your facility:
Operates compressors more than 40 hours/week
Has an aging or unmaintained system
Has noticed rising energy bills or declining performance
Is planning a plant expansion or equipment upgrade
Needs to meet sustainability or ISO standards
Wants to access TVA or local energy efficiency incentives
Service Areas Across Tennessee
Industrial Air Services provides compressed air audits and energy optimization services throughout the state, including:
Nashville, TN
Chattanooga, TN
Knoxville, TN
Clarksville, TN
Murfreesboro, TN
Tri-Cities (Johnson City, Kingsport, Bristol)
Columbia, Jackson, and surrounding towns
Whether your facility is large or small, our team brings the experience and tools to help you reduce waste and increase efficiency.
Why Choose Industrial Air Services?
Industrial Air Services is Tennessee’s trusted partner for compressed air performance. Our audits go beyond finding problems — we build solutions that save you money and help your business grow sustainably.
What Sets Us Apart:
Decades of compressed air experience
Certified technicians and data analysts
Deep knowledge of local industries and regulations
Full service — from audit to implementation
Proven track record with clients across multiple sectors
Final Thoughts
A compressed air audit is one of the most cost-effective tools available to any industrial business looking to cut costs and improve performance. It provides a clear picture of how your system operates and a roadmap for saving energy — often with simple, low-cost changes.
If you’re ready to make your compressed air system smarter, leaner, and more reliable, Industrial Air Services is here to help.
Provided by Industrial Air Services
📍 Serving Nashville, Knoxville, Chattanooga, and all of Tennessee
📞 Call (615) 641-3100 to schedule your compressed air audit today
🌐 Visit www.industrialairservice.com for more details
