Early Warning Signs Your Compressed Air System Will Struggle in the New Year
Compressed air systems rarely fail without warning. More often, they start showing small signs that something isn’t right — signs that are easy to overlook during busy production periods. As the new year begins and production ramps back up, those subtle issues can quickly turn into downtime, higher energy costs, and emergency repairs.
At Industrial Air Services, many January service calls come from systems that were already struggling before the holidays. The signs were there — they just hadn’t reached a breaking point yet. Recognizing these early warning signals gives you a chance to fix problems before they disrupt your operation.
The Compressor Is Running Longer Than It Used To
One of the clearest warning signs is increased run time.
If your compressor:
Runs longer to maintain the same pressure
Rarely shuts off during normal operation
Stays loaded even during lighter demand
…it often indicates leaks, rising demand, control issues, or restrictions in the system. Longer run times translate directly into higher energy costs and accelerated wear.
System Pressure Has Slowly Crept Up
Pressure creep is a classic sign of hidden problems.
Pressure is often raised to compensate for:
Pressure drop at points of use
Undersized piping
Dirty filters
Inadequate storage
Higher pressure may keep production moving, but it masks the real issue while increasing energy use and stress on equipment.
Moisture Is Showing Up Where It Shouldn’t
Water at tools, filters, or equipment is never a good sign.
Moisture issues often point to:
Dryers struggling to keep up
Failed or clogged drains
Poor airflow or ventilation
Condensation from temperature swings
If moisture appeared late last year, it’s likely to get worse as demand increases.
Filters Are Plugging Faster Than Normal
Filters don’t clog overnight.
If you’re replacing filters more often than expected, it usually means:
Increased moisture load
Oil carryover
Rust or debris from piping
Higher airflow than the system was designed for
Rapid filter saturation increases pressure drop and forces the compressor to work harder.
The Compressor Is Running Hotter
Rising operating temperature is a serious warning sign.
Higher temperatures are often caused by:
Dirty coolers
Poor ventilation
Clogged filters
Excessive run time
High ambient temperatures
Heat accelerates oil breakdown and component wear, increasing the likelihood of failure.
Pressure Fluctuates During Normal Operation
Pressure should be stable during routine production.
If pressure:
Drops suddenly when equipment starts
Swings during steady demand
Requires frequent regulator adjustments
…it usually points to storage, piping, or control problems that will worsen as production ramps up.
You’re Hearing More Alarms or Seeing More Faults
Alarms don’t usually increase without reason.
Frequent alarms may indicate:
Overheating
Pressure instability
Electrical stress
Moisture-related issues
Ignoring alarms allows small problems to turn into major failures.
Energy Costs Are Rising Without a Clear Cause
Many facilities notice higher energy bills in January and assume it’s seasonal.
In reality, compressed air inefficiencies often show up as:
Longer run times
Higher demand charges
Increased cycling
Elevated pressure settings
If production hasn’t increased but energy use has, compressed air is often the culprit.
Temporary Fixes Have Become Permanent
Short-term solutions tend to linger.
Examples include:
Bypassed drains
Disabled alarms
Manual overrides
Raised pressure setpoints
These workarounds often signal underlying issues that haven’t been addressed and will eventually cause problems.
Maintenance Is Becoming Reactive Instead of Planned
If maintenance feels like it’s constantly responding to issues instead of preventing them, it’s a sign the system is drifting toward failure.
Frequent small repairs often precede larger breakdowns if root causes aren’t addressed.
The System Hasn’t Been Evaluated in a Long Time
Compressed air systems evolve quietly.
Demand grows, equipment ages, and inefficiencies accumulate. If your system hasn’t been evaluated recently, early warning signs can go unnoticed until they become costly.
Early Action Prevents Year-Long Problems
The start of the year is one of the best times to address compressed air issues. Small adjustments made now can prevent months of inefficiency, downtime, and emergency repairs.
If you’re seeing any of these warning signs, a system evaluation can help identify what’s causing them and what should be addressed first.
Industrial Air Services can help you start the year with a compressed air system that’s stable, efficient, and ready to support production.
Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
