How to Prepare Your Compressed Air System for Increased Production Demand
Increased production is usually a good problem to have — until the compressed air system can’t keep up. As demand rises, weaknesses that were barely noticeable before suddenly become major issues. Pressure drops, moisture shows up, compressors overheat, and downtime creeps in right when production matters most.
At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga prepare their compressed air systems for growth before it causes disruption. Whether demand is increasing seasonally, due to added shifts, or from new equipment, preparation makes all the difference.
Here’s how to get ahead of it.
Start by Understanding How Demand Will Change
Not all production increases affect air systems the same way.
Ask:
Will air usage increase steadily or in short bursts?
Are new machines cycling on and off?
Will demand be higher all day or only during certain shifts?
Are multiple tools starting simultaneously?
Understanding the pattern of demand is more important than knowing the peak number alone.
Verify Your Compressor Can Handle Sustained Load
A compressor that keeps up today may struggle tomorrow.
Signs your compressor may be nearing its limit include:
Running continuously at full load
Higher discharge temperatures
Longer recovery times after demand spikes
More frequent alarms or shutdowns
If the compressor is already working hard, increased demand will push it past safe operating limits.
Add or Reevaluate Air Storage Before Demand Increases
Storage is one of the easiest ways to prepare for higher demand.
Proper storage:
Absorbs short bursts of air usage
Reduces pressure drop during peak demand
Prevents short-cycling
Stabilizes system pressure
In many cases, adding storage delays or even eliminates the need for a larger compressor.
Check Dryer Capacity and Moisture Control
Higher airflow means more moisture entering the system.
When production increases:
Dryers may become overloaded
Dew point can rise
Water may pass downstream
Filters saturate faster
Confirm your dryer is sized for the new airflow, not last year’s conditions — especially in humid climates.
Inspect Piping for Restrictions and Pressure Drop
Increased demand exposes piping weaknesses quickly.
Look for:
Undersized main headers
Long runs with multiple elbows
Corroded or rusted piping
Areas with known pressure loss
Even a strong compressor can’t overcome restrictive piping without wasting energy.
Fix Air Leaks Before Demand Rises
Leaks consume capacity you’ll need later.
As production increases:
Existing leaks become more costly
Pressure drops faster
Compressors run longer to compensate
Leak repair is one of the fastest and least expensive ways to free up air capacity.
Evaluate Controls and Sequencing
Controls that worked under lighter demand may struggle as usage increases.
Watch for:
Compressors loading at the same time
Frequent cycling
Pressure swings during peak use
Poor load sharing
Improved controls help the system respond smoothly instead of reacting late.
Plan for Redundancy and Backup Options
Increased demand raises the stakes when something goes wrong.
Preparation may include:
A secondary or trim compressor
Rental connection points
Load-sharing strategies
Emergency response planning
Even limited redundancy can prevent total shutdown during a failure.
Schedule Preventive Maintenance Ahead of the Ramp-Up
The worst time for maintenance issues is during peak production.
Before demand increases:
Replace filters
Clean coolers
Verify drains
Check oil condition
Inspect belts and electrical components
Preventive service ensures the system is ready to work harder.
Monitor Performance Closely During the Transition
As production ramps up, watch system behavior carefully.
Track:
Run time
Load vs. unload patterns
Pressure stability
Temperature trends
Moisture levels
Early data helps catch issues before they escalate.
Plan for Growth, Not Just the Immediate Increase
Short-term fixes can become long-term problems.
If demand is expected to continue growing:
Design upgrades with expansion in mind
Avoid temporary workarounds
Build flexibility into the system
Planning now saves money and downtime later.
Preparing Your Air System Is Part of Preparing for Growth
Increased production shouldn’t come with increased stress. A compressed air system that’s ready for higher demand supports growth instead of limiting it.
If your facility is planning to ramp up production, add equipment, or increase shifts, we can evaluate your compressed air system and help you prepare before problems appear.
Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing system evaluations, capacity planning, upgrades, and full compressed air support.
📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com
