How to Detect Inefficiencies in Your Compressed Air Controls
Compressed air controls don’t usually fail in obvious ways. When they’re inefficient, the system still runs, tools still work, and production continues — but energy costs climb, compressors wear faster, and pressure stability slowly gets worse. Many facilities live with control problems for years without realizing how much money they’re leaving on the table.
At Industrial Air Services, we routinely find control inefficiencies in systems across Nashville, Knoxville, and Chattanooga, especially in facilities that have grown or changed over time. Here’s how to recognize when your compressed air controls aren’t doing their job.
Your Compressor Runs Even When Demand Is Low
One of the clearest signs of poor control is a compressor that runs unnecessarily.
Watch for:
Compressors running during breaks or off-shifts
Long unloaded run times
Machines staying powered when air demand drops
This usually means the system lacks proper sequencing, demand-based control, or modern automation.
Multiple Compressors Are Fighting Each Other
In multi-compressor systems, poor controls can cause machines to work against one another.
Common symptoms include:
Two compressors loading at the same time when one could handle demand
Compressors rapidly loading and unloading
Uneven run hours between machines
Inconsistent system pressure
When compressors “fight,” energy use skyrockets and wear accelerates.
Pressure Fluctuates More Than It Should
Good controls maintain stable pressure. Bad controls react too late.
If you see:
Pressure swings during normal operation
Operators adjusting regulators frequently
Pressure setpoints creeping higher over time
…it’s often a control logic issue, not a compressor problem.
You’ve Raised System Pressure to Compensate
Increasing pressure is one of the most common ways facilities unknowingly mask control inefficiencies.
Higher pressure is often used to:
Overcome slow response times
Compensate for poor sequencing
Hide storage or piping problems
This wastes energy and shortens equipment life without fixing the root cause.
Compressors Short-Cycle or Switch Modes Frequently
Short-cycling is hard on motors, starters, and controls.
It’s commonly caused by:
Poor load/unload timing
Inadequate storage
Improper control settings
Mismatched compressors
Controls should smooth operation — not create constant transitions.
Older Controls Lack Visibility
Many older control panels provide little insight into how the system actually runs.
Without visibility into:
Load vs. unload time
Run hours
Pressure trends
Alarm history
…it’s impossible to optimize performance or identify inefficiencies early.
Your System Has Grown, But Controls Haven’t
Production changes often outpace control upgrades.
This happens when:
New equipment is added
Shifts increase or change
Demand becomes more variable
A second compressor is installed without proper sequencing
Controls designed for yesterday’s system won’t manage today’s demand efficiently.
Energy Costs Rise Without a Clear Explanation
When controls are inefficient:
Compressors run longer than necessary
Motors draw more power
Peak demand charges increase
If your energy bill keeps climbing but production hasn’t changed, control inefficiencies are a prime suspect.
No Central Control or System Coordination
In many facilities, each compressor operates independently.
This leads to:
Redundant operation
Poor load sharing
Inconsistent pressure
Higher wear across all machines
Centralized control allows the system to behave like a single, coordinated unit instead of separate machines guessing what to do.
Alarms and Faults Occur More Frequently
Poor control logic can push compressors outside their ideal operating range.
This increases:
High-temperature alarms
Pressure-related shutdowns
Electrical faults
Emergency service calls
Better controls keep compressors operating within safe, efficient limits.
Modern Controls Often Deliver the Fastest ROI
Upgrading controls doesn’t always require new compressors.
Modern control solutions can:
Improve sequencing
Reduce energy waste
Stabilize pressure
Extend equipment life
Lower operating costs
In many cases, control upgrades pay for themselves faster than major equipment replacements.
Compressed Air Controls Should Work Quietly in the Background
When controls are doing their job, you barely notice them. Pressure stays stable, compressors run smoothly, and energy costs stay predictable. When controls are inefficient, the system slowly becomes more expensive and less reliable.
If you suspect your compressed air controls aren’t optimized, a system evaluation can quickly identify where improvements will have the biggest impact.
Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing compressed air control evaluations, system optimization, and efficiency upgrades.
📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com
