How Compressed Air Training Can Cut 15–25% Energy Costs for Tennessee Manufacturers
For manufacturers across Tennessee, compressed air is a major utility—essential, but often expensive and inefficient. In fact, the U.S. Department of Energy estimates that as much as 30% of compressed air energy is wasted, primarily due to leaks, poor system design, and improper maintenance. But there’s a powerful (and often overlooked) way to reduce waste and reclaim lost profits: compressed air training.
In this article, we explore how Industrial Air Services’ hands-on training programs can help facilities in Nashville, Knoxville, Chattanooga, and beyond cut energy usage by up to 25%, reduce downtime, and extend the life of their air systems. Whether you’re a plant manager, maintenance supervisor, or technician, this training could be the smartest investment you make all year.
The High Cost of Compressed Air Inefficiencies
Compressed air is widely used for powering tools, operating valves, conveying materials, and controlling automation systems. But it’s also one of the most energy-intensive utilities in a facility—up to 10 times more expensive per unit than electricity.
Common issues that drive up energy usage:
Leaks in piping, fittings, and couplers
Short cycling compressors
Misconfigured unloader valves and control systems
Oversized or undersized dryers
Lack of demand controls
Improper pressure settings or pressure drop across filters
Each of these problems wastes electricity—and every kilowatt-hour wasted shows up on your energy bill.
How Training Eliminates Waste
Compressed air training gives your maintenance and operations staff the skills they need to identify, correct, and prevent inefficiencies. That means:
Fixing issues before they become costly breakdowns
Reducing system pressure to optimal levels
Performing smarter preventative maintenance
Optimizing compressor sequencing and load sharing
Installing or adjusting flow and pressure monitoring tools
Making better upgrade decisions (and qualifying for TVA incentives)
What You’ll Learn in the Industrial Air Services Training
Industrial Air Services offers a two-day Rotary Screw Compressor & Air Dryer Training Class, held regularly in Smyrna, TN, with curriculum designed to target energy-saving opportunities.
Day 1 – Compressors:
How rotary screw compressors work
Control types: load/unload, modulation, VFD
Oil separation and filtration for efficiency
Sequencing multiple compressors
Air storage strategies
Identifying and preventing short cycling
Day 2 – Air Dryers & System Design:
Refrigerated vs. desiccant dryer energy use
Sizing and dew point optimization
Filter selection and pressure drop management
Drain management (automatic vs. manual)
Understanding and reducing pressure loss
Strategies to reduce compressor run time
Participants walk away with clear strategies to immediately cut waste and maintain a leaner, more efficient system.
Real-World Savings: Tennessee Case Studies
📍 Jackson Metal Fabrication Plant
After attending training, a maintenance manager realized their backup compressor was running unnecessarily. They reprogrammed their load-sharing controls and shut off the backup unit during off-peak hours.
Annual Savings: $5,800 in electricity.
📍 Nashville Plastics Facility
A trainee diagnosed excessive moisture downstream and traced it to an incorrectly sized dryer. Industrial Air Services helped replace the unit with a more efficient model, and the technician rebalanced the system to reduce pressure losses.
Annual Savings: $7,200 in avoided compressor overwork and improved dryer operation.
📍 Chattanooga Beverage Company
A lead technician installed flow meters and data loggers after training, helping identify pressure drops across filters and several small leaks. Simple repairs led to measurable savings within 30 days.
Annual Savings: $3,900, plus enhanced system reliability.
TVA EnergyRight Program: Rebate-Friendly Training
Tennessee facilities can offset the cost of training and equipment upgrades through the TVA EnergyRight program. Industrial Air Services is a registered TVA partner and can help you:
Apply for energy audits
Get pre-approved for rebates on training, leak repair, and system upgrades
Document improvements to qualify for incentive payouts
Track energy savings via flow meters and pressure sensors
Training participants are often better equipped to recognize and implement changes that qualify for TVA support.
Who Should Attend?
This training is ideal for:
Plant and facility managers
Maintenance leads
In-house service technicians
Engineers and production supervisors
Contractors supporting industrial facilities
Whether you're maintaining a single compressor or a full plant-wide system, the techniques taught in class are scalable and immediately applicable.
Additional Tools to Maximize Savings
Training is only the beginning. Industrial Air Services can help your team go further with:
Flow meters to track actual usage and benchmark improvements
Three-in-one sensors for real-time pressure, temperature, and flow data
System audits with thermal imaging and ultrasonic leak detection
Hot-tap installations to add drops or sensors without shutting down lines
Custom system design for optimized piping layouts and load balancing
Training gives your staff the foundation. These tools give them the power to act.
Training Options: In-Person and On-Site
Industrial Air Services offers:
Public Training Classes: Held throughout the year in Smyrna, TN. Great for individuals or small teams.
Custom On-Site Training: Delivered directly at your facility, tailored to your equipment and layout. Flexible scheduling for shift coverage.
Training + Audit Combos: Combine hands-on education with a full facility assessment for maximum ROI.
We serve companies across:
Nashville
Knoxville
Chattanooga
Jackson
Tullahoma
Columbia
Murfreesboro
Tri-Cities (Kingsport, Johnson City, Bristol)
And all surrounding areas
How to Get Started
Want to reduce your energy bills and extend the life of your air system? Take the first step:
📞 Call Industrial Air Services at (615) 641-3100
🌐 www.industrialairservice.com
📧 Email info@industrialairservice.com
Our team will help you:
Register for upcoming classes
Plan custom training at your location
Access TVA rebates and documentation
Install monitoring tools to track results
Final Thoughts
When you train your team, you improve your plant. And when your plant runs smarter, cleaner, and more efficiently—everyone wins. Whether you're trying to meet sustainability goals, reduce maintenance costs, or simply run a tighter operation, compressed air training offers a proven path forward.
Don’t leave savings on the table. Let Industrial Air Services help you cut 15–25% in energy costs and future-proof your air system.
