How to Reduce Pressure Drop in Your Compressed Air System
If your tools aren’t hitting as hard as they should or your machines seem sluggish, pressure drop is often the culprit. It’s one of the most common — and most expensive — problems in compressed air systems. The compressor might be producing plenty of air, but by the time that air reaches the point of use, too much pressure has been lost along the way.
The good news? Pressure drop is fixable when you know what’s causing it.
At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga track down the sources of pressure loss and restore smooth, consistent air delivery. Here’s what you need to know about reducing pressure drop and getting your system back to peak performance.
1. Start by Understanding What Pressure Drop Really Is
Pressure drop is the difference between the air pressure leaving the compressor and the pressure available at the point of use. Some drop is normal, but anything over 2–3 PSI is usually a sign of a problem.
Large pressure drops force operators to turn the compressor up to compensate — and every extra 2 PSI increases energy consumption by about 1%. Over time, that adds up to real money.
2. Undersized Piping: The Most Common Cause
One of the biggest contributors to pressure drop is piping that’s too small for the airflow it’s handling. When air is forced through narrow pipes, friction increases and pressure falls.
Signs your piping might be undersized:
Pressure drops whenever multiple tools run
Airflow is inconsistent at far-end workstations
Your compressor seems to “work harder” than it should
The fix is simple: upsizing key sections of your piping or switching to a loop system instead of a dead-end run. Even a one-size increase in diameter can drastically reduce pressure loss.
3. Long Runs and Excessive Fittings Add Resistance
Every foot of pipe adds friction. Every elbow, tee, or quick-connect adds turbulence. The more complicated the path from compressor to tool, the more pressure you lose.
To reduce unnecessary resistance:
Keep piping runs as short and straight as possible
Use sweep elbows instead of sharp 90-degree turns
Minimize tees and redundant fittings
Remove unused drops or obsolete branches
A cleaner, simpler piping layout always performs better.
4. Dirty or Clogged Filters Restrict Airflow
Filters protect your air quality, but when they clog, they act like bottlenecks. This causes significant pressure loss, especially during peak demand.
If you notice a sudden pressure change, your filters might be:
Saturated with oil
Loaded with dust or particulates
Overdue for replacement
Replace filters on schedule — and consider upsizing filters if they’re consistently restricting airflow.
5. Moisture Buildup Creates Flow Restrictions
Water in your piping reduces flow, increases corrosion, and can block narrow passages. Tennessee humidity makes this a big issue.
Moisture-related pressure drop often comes from:
Undersized or neglected air dryers
Failed condensate drains
Low spots in piping where water pools
Keeping your system dry is one of the simplest ways to maintain consistent pressure.
6. Leaks Steal Pressure and Waste Energy
Even small leaks add up. A single 1/8-inch leak can waste hundreds of dollars a year in energy — and lower pressure across the entire system.
Look for leaks around:
Joints and fittings
Quick-connects
Valve stems
Hose connections
Ultrasonic leak detection or even old-fashioned soap-and-water testing can help track them down quickly.
7. Check Your Regulators and Valves
Malfunctioning regulators or partially closed valves can choke airflow without you realizing it. If you see pressure drop occurring only downstream of a specific regulator or valve, that component is likely restricting flow.
A quick check and adjustment — or replacement — can restore normal pressure instantly.
8. Increase Storage for Better Pressure Stability
Receiver tanks act as pressure stabilizers. If your plant experiences sudden spikes in demand, adding more storage can keep pressure steady and reduce cycling.
A good rule of thumb: aim for 1 gallon of storage per CFM of compressor capacity. Many facilities benefit from adding secondary storage closer to high-demand areas.
9. Optimize System Pressure (Don’t Just Crank It Up)
Raising compressor pressure is often the first thing people do when they see drop — but this masks the real issue and wastes energy. Instead, identify and fix the root cause.
Once the drop is resolved, you’ll likely be able to lower your system pressure, saving energy and reducing stress on your equipment.
10. Get a Professional System Audit
Pressure drop has many possible causes, and in complex facilities, you need real data to diagnose it accurately.
A professional air system audit can:
Map pressure throughout the system
Identify bottlenecks and restrictions
Measure flow and demand
Reveal issues you can’t see visually
At Industrial Air Services, we use this data to provide clear, actionable recommendations that eliminate pressure drop and improve system performance.
Reliable Pressure = Reliable Production
Pressure drop slows tools, reduces throughput, and drives up energy costs — but it doesn’t have to be part of your daily routine. With the right maintenance, piping design, and filtration, your air system can deliver strong, consistent pressure to every point of use.
If you’re noticing sluggish tools or wide pressure swings, don’t just adjust the regulator — let us help you find and fix the root cause.
Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing air compressor service, system audits, piping upgrades, and preventive maintenance to keep your air supply consistent and efficient.
📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com
