How to Troubleshoot Low Air Pressure in Your Compressor System

Few things bring production to a halt faster than low air pressure. When your air tools start losing power or your equipment won’t cycle correctly, it’s more than an inconvenience — it’s lost time, lost output, and higher operating costs.

The good news is that most low-pressure problems have clear, fixable causes. Understanding where to look (and what to look for) can help you get your system back on track quickly.

At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga diagnose and fix low-pressure issues every day. Here’s how you can troubleshoot the problem safely before it turns into costly downtime.

1. Start with the Simple Checks

Before diving into the system, begin with the basics.

• Confirm pressure settings: Make sure your pressure switch or controller is set to the correct cut-in and cut-out range. Sometimes a setting gets bumped, causing the compressor to run at a lower pressure.

• Check your gauges: A faulty or inaccurate gauge can lead you in the wrong direction. Compare readings at multiple points — the tank, dryer, and point of use.

• Inspect for power issues: Low voltage or electrical irregularities can cause the compressor to underperform. Ensure the power supply matches the machine’s specifications.

2. Listen for Leaks

Air leaks are the most common cause of low system pressure — and they’re often easy to overlook.

Walk the length of your piping and listen for hissing. Check fittings, quick connects, hoses, and couplings. Even a small hole can drain significant air volume.

If you can’t hear anything, that doesn’t mean you’re leak-free. Some leaks are ultrasonic — too high-pitched to detect by ear. Our technicians use specialized detection tools to pinpoint those invisible leaks and measure their impact on your pressure and energy costs.

3. Check Filters and Separators

Dirty filters are silent pressure killers. As filters trap dust, oil, and moisture, they become restricted, choking airflow through the system.

Inspect and replace:

• Compressor inlet filters – restrict intake airflow when clogged.

• Coalescing filters – can cause pressure drop if saturated with oil or water.

• Particulate filters – collect fine debris that accumulates over time.

If your filters haven’t been changed recently, replacing them is one of the quickest and cheapest ways to restore pressure.

4. Inspect the Air Dryer

A malfunctioning air dryer can cause more than moisture problems — it can also restrict airflow.

Refrigerated dryers can develop frozen heat exchangers, while desiccant dryers may have clogged purge valves or saturated desiccant beds. Both conditions create resistance and drop pressure downstream.

Check your dryer’s pressure differential. If you see more than a few PSI drop across the unit, it’s time for cleaning or service.

5. Examine the Piping System

Your piping layout has a huge influence on air pressure stability.

Look for:

• Undersized piping that can’t handle your airflow demand.

• Long runs with too many bends that increase friction loss.

• Old or corroded lines that reduce flow and leak at the joints.

A properly designed system minimizes these losses. We often recommend looped piping layouts, which let air flow from multiple directions to balance pressure across your entire facility.

6. Check for Excessive Demand

Sometimes the problem isn’t supply — it’s demand.

If new equipment was added or production has increased, your air system may be undersized for current usage. When demand spikes beyond capacity, pressure drops everywhere.

You can confirm this by checking system pressure at different times of day. If it falls off during peak production but recovers afterward, demand management — or additional storage — may be the answer.

7. Inspect Drains and Moisture Traps

Condensate drains that are stuck open can waste huge amounts of air. Every second a drain blows air instead of water, your compressor is fighting to replace that lost pressure.

Automatic drains should be checked regularly to make sure they’re cycling properly. If they’re old or unreliable, consider upgrading to zero-loss electronic drains — they discharge water without losing air.

8. Review the Receiver Tank

Receiver tanks help smooth out pressure fluctuations and store reserve air. If the tank is undersized or isolated by a restricted valve, it can’t stabilize pressure properly.

Check that the tank’s isolation valves are fully open and that the tank itself is sized for your compressor output and system needs. As a rule of thumb, the receiver capacity should be at least 1 gallon per CFM of compressor flow, though high-demand systems often need more.

9. Evaluate the Compressor’s Output

If everything downstream checks out, the compressor itself may be the issue.

Look for warning signs like:

• Longer-than-normal cycle times

• Excessive heat or noise

• Oil carryover or moisture in discharge air

• Motor overload trips

Low output can stem from worn air ends, failing valves, or oil separation issues. A simple airflow test performed by a technician can confirm whether your compressor is producing its rated CFM.

10. Don’t Overlook the Obvious

It sounds simple, but sometimes the root cause of low pressure is a partially closed valve, a kinked hose, or a clogged quick-connect fitting.

Walk the system slowly with a fresh set of eyes. Check each valve, hose, and regulator. You might spot something small that makes a big difference.

When to Call a Professional

If your system has multiple compressors, dryers, and filters, or if pressure fluctuates inconsistently across zones, it’s time for a professional assessment.

At Industrial Air Services, our technicians use precision pressure mapping tools to locate the exact points of loss — whether it’s a leak, restriction, or control issue. We can test flow, check for system imbalance, and restore your air pressure to peak performance quickly and safely.

Consistent Pressure Means Consistent Productivity

Low air pressure isn’t just a maintenance nuisance — it’s a productivity drain. Taking the time to diagnose the issue properly will not only restore performance but also protect your compressor from unnecessary wear.

A stable, balanced air system delivers better tool performance, higher energy efficiency, and fewer headaches for everyone on the floor.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, offering expert compressed air troubleshooting, repairs, and maintenance to keep your system running strong all year.

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