Common Compressed Air Mistakes Facilities Plan to Fix Next Year

As the year comes to a close, many facilities start taking an honest look at what worked, what didn’t, and what they want to improve going forward. When it comes to compressed air systems, the same issues tend to rise to the top year after year. They’re not always urgent, but they quietly increase costs, create inefficiencies, and lead to avoidable downtime.

At Industrial Air Services, we hear the same refrains every December from facilities across Middle Tennessee: “We’ve been meaning to address that,” or “That’s something we need to fix next year.” Here are the most common compressed air mistakes facilities plan to correct — and why it makes sense to finally tackle them.

Running the System at Higher Pressure Than Necessary

This is one of the most common habits facilities want to undo.

Pressure often gets turned up to compensate for pressure drop, leaks, growing demand, or undersized piping. While it may keep tools running, higher pressure increases energy consumption, worsens leaks, and adds unnecessary strain to equipment. Many facilities plan to lower system pressure once the real issues are addressed.

Ignoring Small Air Leaks

Small leaks are easy to ignore because production keeps moving.

They’re often left alone because the compressor still keeps up and no one feels an immediate impact. Over time, though, those leaks force the compressor to run longer and hotter, driving up energy costs. Fixing leaks is one of the fastest ways facilities free up air capacity heading into the new year.

Relying on Emergency Repairs Instead of Preventive Maintenance

Reactive maintenance is stressful and expensive.

Facilities often decide they want to move away from after-hours service calls, weekend breakdowns, rushed decisions, and unplanned downtime. Preventive maintenance helps stabilize costs, reduce emergencies, and keep compressors running efficiently throughout the year.

Living With Inconsistent Pressure

Pressure fluctuations often become accepted as “normal.”

Operators adjust regulators or work around weak tools instead of fixing the underlying problem. Inconsistent pressure usually points to issues with storage, piping, or controls — issues many facilities plan to finally address rather than compensate for.

Putting Off Piping Upgrades Too Long

Old or undersized piping quietly limits performance.

Pressure drop, moisture problems, rust contamination, frequent leaks, and excessive noise often trace back to aging piping. Many facilities know piping is part of the problem but delay upgrades because the system still works. By year-end, it often becomes clear that a long-term fix is overdue.

Accepting Moisture as Part of the System

Water in compressed air should never be considered normal.

Facilities often justify moisture by saying it only happens part of the year or that tanks get drained “when someone remembers.” Over time, moisture leads to corrosion, tool damage, and product issues. Many facilities plan to address moisture properly through better dryers, drains, and storage.

Not Tracking System Performance

Many compressed air systems operate with little visibility.

Without tracking run hours, load versus unload time, pressure trends, or energy use, inefficiencies go unnoticed. Gaining better insight into system performance is a common goal for the new year.

Delaying Air Storage Improvements

Undersized or poorly placed receiver tanks cause short-cycling, pressure instability, dryer overload, and increased energy use. Storage upgrades are often postponed, but many facilities plan to add or relocate tanks once they see how much storage affects efficiency.

Operating With No Backup Air Plan

Single-compressor systems carry significant risk.

Facilities often realize that a single failure could shut down production and that emergency rentals aren’t always immediately available. Planning some level of backup air becomes a priority heading into the new year.

Waiting Too Long to Evaluate the Whole System

Compressed air systems evolve quietly.

Demand grows, equipment ages, and temporary fixes become permanent. By the end of the year, many facilities recognize that a system evaluation would help prioritize improvements and avoid repeating the same problems next year.

The New Year Is the Right Time to Reset

Most compressed air mistakes don’t come from neglect — they come from growth, changing production needs, and short-term fixes that stuck around too long. The new year offers a clean slate to reset habits and build a system that runs more efficiently and reliably.

If your facility has a compressed air improvement list for the coming year, Industrial Air Services can help you prioritize it and turn plans into practical upgrades.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com