Compressed Air Energy Audits for Knoxville Facilities: Real Savings, Real Results
Compressed air is essential to manufacturing—but it’s also one of the most expensive utilities in your facility. What many Knoxville plant managers don’t realize is that up to 50% of compressed air energy is wasted through leaks, misapplications, and inefficiencies.
That’s why more facilities across East Tennessee are investing in compressed air energy audits—a smart, fast, and cost-effective way to uncover waste, lower utility bills, and boost system performance.
In this blog, we’ll break down what an energy audit involves, how it can help your operation, and what kind of results Knoxville-area businesses are seeing when they work with Industrial Air Services.
Why Energy Audits Matter in Knoxville
Knoxville is home to a diverse and growing industrial base, from metal fabrication shops and automotive suppliers to food processors and packaging plants. Many of these operations run multiple compressors 24/7 to meet production demands. But unlike electricity or water, compressed air is invisible, so problems often go unnoticed—until they show up on your power bill.
Here’s the truth: every CFM of air costs you money. And every leak, overpressurized tool, or oversized compressor is a direct hit to your bottom line. A compressed air energy audit identifies those issues and shows you exactly how much they’re costing.
For most Knoxville facilities, an audit will reveal thousands—sometimes tens of thousands—of dollars in annual energy waste. And the best part? Most of those issues are simple to fix.
What’s Included in a Compressed Air Energy Audit?
At Industrial Air Services, our Knoxville energy audits are comprehensive, data-driven, and customized to your facility. Here’s what you can expect:
System Monitoring and Data Logging
We use advanced monitoring tools to track air usage, pressure, temperature, and system cycles over several days. This gives us a real-world picture of your compressor’s behavior during startup, shutdown, peak production, and idle times.
Leak Detection
Leaks are one of the most common sources of waste—sometimes accounting for 20–30% of total air loss. We use ultrasonic leak detectors to locate even the smallest leaks, which are often silent and hard to spot during normal operations.
Demand-Side Analysis
We look at how air is used throughout your facility—tools, machinery, controls, blow-off applications, etc.—to identify areas of overuse or inefficient practices.
Compressor Control Evaluation
Are your compressors staged properly? Is one unit always running at partial load? Are older machines operating inefficiently alongside newer ones? We analyze your control strategy to reduce unnecessary runtime and load imbalance.
Pressure Optimization
We determine if your system is over-pressurized, which is common in facilities trying to “push” air to the furthest drops. Reducing pressure—even by 2-3 PSI—can significantly cut power usage without impacting performance.
Recommendations and ROI Reporting
You’ll receive a full report outlining issues, solutions, and estimated energy savings. We’ll even calculate payback periods for fixes like leak repair, dryer upgrades, new controls, or variable-speed compressors.
Real Savings for Knoxville Facilities
We’ve completed energy audits for facilities across Knoxville and surrounding counties—and the results speak for themselves:
Example 1: Automotive Parts Manufacturer in Maryville
Discovered 17 air leaks and multiple oversized tools running at 120 PSI. Adjusted pressure to 100 PSI and repaired leaks.
Annual savings: $8,400
Payback time: 3 months
Example 2: Food Processing Plant in East Knoxville
Identified inefficient load/unload control setup. Installed VSD compressor and optimized dryer system.
Annual savings: $12,000
Improved system stability and product consistency
Example 3: Packaging Line in Sevierville
Audit revealed after-hours air demand caused by left-on blow-off systems. Installed auto shutoff valves.
Annual savings: $5,200
Eliminated unnecessary overnight runtime
Even smaller facilities—like fabrication shops or distribution centers—see measurable benefits from targeted energy audits.
Why Audits Are Especially Useful in Humid Knoxville Summers
Humidity plays a big role in compressed air performance. In Knoxville, summer humidity often reaches 80–90%, increasing moisture load on your system. This leads to higher energy use, increased wear on dryers and filters, and more maintenance issues.
An energy audit during summer months can uncover climate-related inefficiencies, such as:
Oversized dryers running inefficiently
Water accumulation in piping systems due to poor drainage design
High pressure drop from saturated filters
Unnecessary compressor cycling due to temperature-driven fluctuations
Addressing these issues during peak humidity helps you avoid downtime and reduce costs when your system is under the most strain.
When Should You Schedule an Energy Audit?
You should consider scheduling a compressed air audit in Knoxville if:
Your energy bills have increased without a clear reason
You’ve recently expanded your facility or added equipment
Your compressors run frequently at partial load
You’re running multiple compressors and not sure if they’re staged efficiently
Your air tools underperform or your system experiences pressure fluctuations
You’ve never had a professional compressed air evaluation
Even if your system seems to be working fine, an audit often uncovers hidden problems that are costing more than you realize.
We Make the Process Easy
At Industrial Air Services, our audits are designed to fit your schedule and workflow. Here's how it works:
Initial Consultation – We review your system size, usage, and goals.
Site Visit – We install data loggers and inspect key components.
Data Collection – Over a 3–7 day period, we monitor real-time system behavior.
Analysis and Reporting – You get a clear, actionable report with findings and recommendations.
Support and Implementation – We help implement fixes, whether it’s leak repair, control upgrades, or system redesign.
No pressure. No obligation. Just the information you need to run a better system.
Why Knoxville Chooses Industrial Air Services
We’re not just energy auditors—we’re compressed air experts. Our Knoxville-based team understands the unique challenges East Tennessee manufacturers face, and we back up our audits with real solutions.
Local Technicians who know your industry and climate
Brand-Agnostic Audits – We service all makes and models
End-to-End Service – From data to implementation
Documented ROI for budget justification and management approval
Follow-Up Support to make sure improvements stick
Our audits go beyond basic troubleshooting—we give you a long-term efficiency strategy.
Proudly Serving Knoxville and East Tennessee
We conduct air system audits across the region, including:
Knoxville
Oak Ridge
Maryville
Alcoa
Sevierville
Lenoir City
Jefferson City
Clinton
Loudon
No matter your industry, size, or compressor brand, we can help you save energy and improve performance.
Let’s Find Your Hidden Savings
Think of a compressed air energy audit as a health checkup for your system. It costs little compared to what it can save—and it gives you the information you need to make smarter decisions going forward.
Call Industrial Air Services at (615) 641-3100 to schedule your compressed air energy audit in Knoxville or the surrounding area.
Let’s eliminate waste, boost performance, and uncover real savings—together.
