How Undersized Piping Restricts Airflow and Raises Energy Costs
When compressed air systems struggle, the compressor usually gets the blame. But in many facilities, the real problem isn’t the compressor at all — it’s the piping.
Across manufacturing plants, fabrication shops, automotive facilities, and production floors in Nashville, LaVergne, Murfreesboro, Smyrna, and throughout Rutherford, Davidson, and Hamilton Counties, undersized or outdated piping is one of the most common causes of poor airflow, pressure problems, and rising energy costs.
Piping doesn’t wear out loudly. It quietly becomes a bottleneck that forces the entire system to work harder than it should.
Why Piping Size Matters More Than Most People Think
Compressed air needs room to move.
When piping is undersized, airflow becomes restricted as demand increases. The compressor may be producing enough air, but that air can’t move through the system fast enough to reach tools and equipment at the pressure they need.
The result is familiar:
Pressure drops during peak demand
Tools lose power
Compressors run longer
Operators turn pressure up to compensate
That compensation is where energy costs begin to climb.
Undersized Piping Creates Pressure Drop Everywhere
Pressure drop isn’t caused by one big restriction — it’s caused by many small ones adding up.
Undersized piping increases friction inside the line. As airflow speeds up to meet demand, friction rises sharply. That friction turns into pressure loss, especially during high-use periods.
In older facilities or growing plants, we often see:
Pipe sizes that were adequate years ago but no longer match demand
Long runs of small-diameter pipe feeding high-use areas
Branch lines that choke airflow to tools and machines
Even a system that “mostly works” can be losing significant pressure every day.
Why Pressure Gets Turned Up (and Why That’s Costly)
When airflow is restricted, the most common response is to raise system pressure at the compressor.
This feels like a quick fix, but it creates a chain reaction:
Higher pressure increases energy consumption
Leaks waste more air
Compressors run hotter and longer
Wear accelerates on equipment
The underlying piping problem doesn’t go away — it just becomes more expensive.
Small Pipe Changes Can Have Big Consequences
Many piping problems start with well-meaning changes.
Over time, systems evolve:
New machines get tied into existing lines
Temporary drops become permanent
Small extensions get added without upsizing mains
Equipment is relocated without rethinking airflow
Each change may seem minor, but together they can dramatically reduce system performance.
Long Runs and Too Many Elbows Make It Worse
Pipe diameter isn’t the only factor — layout matters too.
Undersized piping combined with:
Long pipe runs
Excessive elbows and tees
Sharp turns instead of sweeps
…creates even more resistance. Every turn adds friction, and in a small pipe, that friction adds up fast.
This is why some tools work fine close to the compressor but struggle farther away.
Undersized Piping Forces Compressors to Work Harder
When airflow is restricted, the compressor compensates by running longer to maintain pressure.
That leads to:
Increased run time
Higher operating temperatures
Greater electrical demand
Shorter service intervals
Over time, the compressor wears out faster — even though the root cause lives in the piping.
Energy Costs Rise Quietly With Piping Restrictions
Undersized piping is a hidden energy drain.
Facilities often notice:
Rising power bills
Longer compressor run hours
More frequent maintenance
…but don’t connect those costs back to airflow restrictions. Because piping issues don’t trigger alarms, they quietly drive expenses month after month.
Signs Your Facility May Have Undersized Piping
Common indicators include:
Pressure drops during peak usage
Tools losing power when multiple stations run
Compressors rarely unloading
Pressure higher at the compressor than at points of use
Operators compensating with regulators
If these sound familiar, piping size is worth evaluating.
Fixing Piping Issues Doesn’t Always Mean a Full Replacement
The good news is that piping improvements don’t always require a complete system overhaul.
In many cases, improvements include:
Upsizing main headers
Adding parallel runs to reduce restriction
Rerouting airflow to shorten long runs
Reducing unnecessary elbows and fittings
Improving loop design
Even targeted upgrades can significantly reduce pressure drop and energy use.
Properly Sized Piping Improves the Entire System
When airflow restrictions are removed:
Pressure stabilizes
Compressors cycle properly
Energy consumption drops
Tool performance improves
Maintenance demands decrease
The entire system runs smoother — without pushing equipment beyond its limits.
A System View Delivers the Best Results
Undersized piping is rarely an isolated issue. It often works alongside:
Inadequate air storage
Leaks
Moisture problems
Outdated layouts
Evaluating piping as part of the whole compressed air system leads to better, longer-lasting solutions.
Local Expertise Makes the Difference
At Industrial Air Services, we help facilities across Nashville, LaVergne, Murfreesboro, Smyrna, Knoxville, and Chattanooga identify airflow restrictions and design piping solutions that reduce pressure drop and energy costs. From system evaluations to targeted piping upgrades, we focus on practical improvements that deliver measurable results.
If your compressor seems to be working harder than it should, undersized piping may be the silent bottleneck driving up your operating costs.
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
