How to Tell If Your Air Compressor Is Wasting Energy

Compressed air is one of the most expensive utilities in a facility, yet it’s also one of the easiest places for energy waste to hide. Unlike lighting or HVAC, compressed air inefficiencies aren’t always obvious. The system still runs, tools still work, and production keeps moving — but behind the scenes, your compressor may be burning far more electricity than necessary.

At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga identify where energy is being lost in their air systems and how to correct it. Here are the most common signs your compressor is wasting energy — and what they usually mean.

1. Your Compressor Runs Constantly, Even During Light Production

A compressor that rarely shuts off is a major red flag.

Common causes include:

• Air leaks

• Undersized storage

• Pressure set too high

• Demand exceeding system capacity

• Poor controls or outdated sequencing

Even small leaks can force a compressor to run nonstop, quietly driving up your electric bill.

2. Your Energy Bills Keep Rising Without a Production Increase

If production hasn’t changed but your power bill has, compressed air is often the culprit.

Energy waste shows up as:

• Higher kWh usage

• Increased peak demand charges

• Longer compressor run times

• Motors pulling more amps

Compressed air inefficiencies compound quickly — especially during hot, humid Tennessee summers.

3. You’ve Raised System Pressure to “Fix” Performance Issues

Increasing PSI is one of the most expensive band-aids in compressed air systems.

For every 2 PSI increase, energy use rises by roughly 1%.

If your pressure has crept up over time, it often means:

• Leaks haven’t been fixed

• Piping is undersized

• Filters are clogged

• Storage is inadequate

Higher pressure doesn’t fix problems — it just hides them while wasting energy.

4. Your Compressor Short-Cycles or Rapidly Loads and Unloads

Excessive cycling wastes energy and wears out components.

Short-cycling is usually caused by:

• Too little air storage

• Sudden demand spikes

• Leaks

• Poor control logic

Each start-up pulls a surge of power, which adds up fast over time.

5. Filters Are Plugging Faster Than Normal

Dirty filters increase pressure drop, forcing the compressor to work harder.

When filters clog quickly, it often points to:

• Moisture overload

• Oil carryover

• Rust from piping

• Poor dryer performance

The compressor compensates by consuming more energy to maintain pressure.

6. Your Compressor Runs Hotter Than It Used To

Heat and inefficiency go hand in hand.

A compressor that runs hot is usually:

• Working too hard

• Starved for airflow

• Poorly ventilated

• Running at excessive pressure

Higher temperatures reduce efficiency and shorten oil and component life.

7. You Hear Air Leaks but Haven’t Addressed Them

Leaks are one of the largest sources of wasted compressed air.

A single ⅛-inch leak can cost thousands of dollars per year in energy alone.

Leaks commonly occur at:

• Quick-connect fittings

• Hoses and reels

• Regulators

• Valves

• Old piping joints

If you can hear leaks, you’re definitely paying for them.

8. Your Compressor Is Older and Lacks Modern Controls

Older fixed-speed compressors run at full output whether you need the air or not.

Without modern controls:

• The compressor wastes air during unload cycles

• Power consumption stays high during low demand

• Energy savings opportunities are missed

Newer control strategies and VSD technology dramatically reduce wasted energy.

9. You Don’t Have Visibility Into Run Time or Power Draw

If you’re not tracking:

• Hours run

• Load vs. unload time

• Amp draw

• Pressure trends

…it’s almost impossible to know how much energy is being wasted.

Monitoring reveals inefficiencies that otherwise go unnoticed.

10. Your System Has Never Been Audited

Many facilities operate for years without a compressed air audit.

An audit identifies:

• Leaks

• Pressure drop

• Oversized or undersized equipment

• Storage issues

• Control inefficiencies

Most audits uncover enough waste to pay for themselves quickly.

Energy Waste in Compressed Air Is Common — but Fixable

Compressed air systems naturally drift toward inefficiency over time. Leaks develop, demand grows, and settings get adjusted without addressing root causes. The good news is that most energy waste can be corrected with targeted improvements — often without replacing the compressor.

If you suspect your system is wasting energy, we can evaluate it and show you exactly where savings are hiding.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing energy audits, leak detection, system optimization, and full compressed air service.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com