How to Lower Your Energy Bills with a Compressed Air Audit
Compressed air is often referred to as the "fourth utility" in manufacturing — and it’s also one of the most expensive. In fact, compressed air systems can account for up to 30% of a facility’s total energy usage. What’s more surprising is that as much as 50% of that energy is wasted due to leaks, poor system design, and inefficient equipment.
That’s why a compressed air audit is one of the smartest investments you can make. At Industrial Air Services, we perform professional air audits for businesses across Nashville, Knoxville, and Chattanooga, helping them cut energy costs, boost productivity, and improve system reliability.
If you're looking for real, measurable savings — this is where to start.
What Is a Compressed Air Audit?
A compressed air audit is a detailed analysis of your entire air system, from the compressor room to point-of-use. The goal is to identify where your system is losing energy, where improvements can be made, and what steps will lead to the greatest cost savings.
A proper audit looks at:
Air leaks
Pressure drops
Compressor sizing and runtime
Inappropriate uses of compressed air
Air treatment and piping inefficiencies
System controls and automation
Using tools like data loggers, ultrasonic leak detectors, flow meters, and pressure sensors, our team collects real-world data from your facility and turns it into actionable insights.
Why Is an Air Audit So Important?
Most facilities don’t know how much energy they’re wasting — and without a data-driven audit, there’s no way to find out.
Here are the top reasons an audit can dramatically reduce your energy bills:
1. Leaks Can Waste Thousands Per Year
Even a 1/8" leak in a 100 PSI system can waste over $2,500 worth of electricity per year. Multiply that by multiple leaks across a plant, and the cost skyrockets. Audits locate and quantify leaks, allowing you to prioritize repairs.
2. Improper System Pressure Wastes Energy
Running your compressor at 110 PSI when your tools only require 90 PSI doesn’t just increase energy use — it increases wear and tear on your equipment. An audit can determine the lowest effective pressure your system needs to function efficiently.
3. Undersized or Oversized Compressors Burn Money
A compressor that’s too small will run constantly and fail early. A compressor that’s too large will short-cycle and waste power. Air audits help determine the right size and configuration for your actual demand.
4. Poor Piping Layouts Cause Pressure Drops
Long piping runs, sharp elbows, and undersized pipe diameter can cause major pressure losses. This forces your compressor to work harder than it should. A system layout analysis can eliminate unnecessary restrictions.
5. Unnecessary Uses of Compressed Air
Many plants use compressed air for jobs it wasn’t designed for — like cooling parts, sweeping floors, or ventilating spaces. These applications drive up energy costs without adding value. Audits identify where other tools (like electric blowers) may be better suited.
What’s Included in a Professional Air Audit?
At Industrial Air Services, we tailor our compressed air audits to your facility's needs. Our process typically includes:
Site walk-through and system mapping
Baseline energy measurement
Compressor load analysis
Pressure profiling throughout the system
Leak detection and documentation
Demand vs supply comparison
Review of air treatment and filtration
Recommendations for upgrades or adjustments
We provide a comprehensive report showing your current system performance, where energy is being lost, and how to improve efficiency.
Real Results: What Kind of Savings Can You Expect?
While every facility is different, most companies we audit see:
10–35% reduction in energy usage
Improved air quality and system reliability
Longer compressor lifespan
Fewer unplanned outages
Faster ROI on equipment upgrades
Even simple changes — like lowering system pressure or fixing a few key leaks — can make a huge difference in your monthly energy bills.
Who Should Schedule an Air Audit?
An audit is especially valuable if:
Your energy bills are rising and you don’t know why
You’ve expanded production without upgrading your compressor
You experience unexplained pressure drops or tool malfunctions
Your compressors are running almost constantly
You’re planning a facility expansion or equipment replacement
You want to qualify for utility rebates or energy incentives
Our customers range from small machine shops to large-scale manufacturers — and nearly all of them discover cost-saving opportunities they didn’t expect.
Are There Rebates or Incentives Available?
Yes! Many Tennessee utility companies offer cash rebates or energy efficiency incentives for businesses that improve compressed air efficiency. These programs often cover:
Leak repair
Equipment upgrades
Energy-efficient compressor replacements
System monitoring
Industrial Air Services can help you navigate these rebate programs and supply the documentation needed to apply.
What Happens After the Audit?
After completing your audit, we don’t just hand you a report and walk away. We help you implement solutions that work.
That might include:
Installing smarter compressor controls
Replacing or resizing compressors
Upgrading piping systems
Repairing or replacing dryers, filters, and drains
Designing a preventive maintenance plan to sustain results
With our local service teams in Nashville, Knoxville, and Chattanooga, we’ll continue to support your system for the long haul.
Ready to Save Energy and Improve Your System?
A compressed air audit is the fastest way to lower operating costs — and the smartest way to future-proof your operation.
📞 Call Industrial Air Services at (615) 641-3100 today to schedule your audit or speak with one of our system specialists.
Whether you’re running a single shift or a 24/7 facility, we’ll help you cut waste, improve performance, and protect your bottom line.
Don’t let energy waste hide in your air lines. Let us help you uncover the savings with a compressed air audit built for Tennessee industries.
