Nashville Case Study: How Leak Detection Saved a Manufacturer Thousands

Compressed air is one of the most expensive utilities for industrial facilities — even more than electricity, water, or gas when you consider how much energy it takes to produce. Yet, in Nashville, many manufacturers treat compressed air as “free.” What often gets overlooked is the fact that up to 30% of compressed air is wasted through leaks.

These leaks aren’t just a nuisance. They directly increase energy bills, shorten compressor life, and reduce system performance. In this case study, we’ll look at how a Nashville manufacturer tackled air leaks with the help of Industrial Air Services — and how leak detection turned into tens of thousands of dollars in savings.

The Manufacturer: A Metal Fabrication Facility in Nashville

The facility, located in an industrial park near I-24, relied heavily on compressed air to power pneumatic tools, automated equipment, and production lines. Their compressors ran almost continuously to meet demand.

But the plant manager noticed a problem:

Energy costs were rising each quarter.

Compressors ran almost nonstop, even when production slowed.

Employees complained about inconsistent tool performance.

Despite investing in routine maintenance, the company couldn’t figure out why the system struggled to keep up.

The Problem: Hidden Air Leaks

Like many facilities, this manufacturer had leaks hidden throughout its compressed air system. Leaks were draining capacity, causing compressors to work harder, and driving up energy costs.

Some facts about leaks:

A single 1/8-inch leak at 100 psi wastes over 26 cubic feet of air per minute, costing about $1,200 annually in electricity.

A 1/4-inch leak can cost more than $8,000 per year.

In a typical plant, leaks waste 20–30% of total compressed air output.

Without professional detection, many leaks remain invisible.

Step 1: Comprehensive Leak Detection Audit

The facility contacted Industrial Air Services to perform a full compressed air audit.

Tools and Techniques Used

Ultrasonic Detectors: Picked up high-frequency sounds from leaks, even in noisy production areas.

Pressure Monitoring: Identified pressure drops caused by leaks.

Airflow Analysis: Measured output to compare against actual demand.

Findings

37 leaks were identified across the plant.

Most leaks were at couplings, hoses, and fittings.

One major leak at a quick-disconnect fitting was wasting nearly $5,000 per year alone.

Step 2: Repairs and Upgrades

After identifying the leaks, IAS technicians:

Replaced worn hoses and fittings.

Repaired leaking couplings and valves.

Recommended upgraded quick-connects designed to minimize leaks.

Installed new filters and dryers to improve air quality and efficiency.

The Results: Massive Savings and Better Performance

Within three months of repairs, the manufacturer saw measurable improvements:

Energy costs dropped 22%.

Compressor run time decreased — no longer running 24/7, extending equipment life.

Tool performance improved, reducing complaints from employees.

Estimated annual savings exceeded $40,000.

In addition, the company avoided an unnecessary investment in a new compressor. They had considered buying a larger unit to keep up with demand, but leak detection revealed that their current system was more than adequate once leaks were fixed.

Why Leak Detection Matters for Nashville Manufacturers

This case study highlights why leak detection is one of the fastest and most effective ways to save money in industrial operations:

Immediate ROI

Repairs pay for themselves within months.

Improved Reliability

Compressors don’t work as hard, reducing failures and maintenance needs.

Energy Efficiency

Lower electricity use means lower bills and greener operations.

Extended Equipment Life

Reduced strain adds years to compressor lifespan.

Compliance Benefits

For food and healthcare industries, fewer leaks mean cleaner, drier air.

Local Impact: Why This Matters in Nashville

Nashville’s growing industrial base means higher competition and tighter margins. From automotive suppliers in La Vergne and Smyrna to healthcare product manufacturers in Davidson County, businesses are looking for ways to cut costs without sacrificing quality.

Energy efficiency is one of the easiest ways to achieve this — and compressed air leak detection is a proven, low-cost solution.

Other Case Examples in Middle Tennessee

Case #1: Food Processing Facility

A Nashville food processor struggled with high energy bills. Leak detection uncovered 25 leaks wasting nearly $20,000 annually. Repairs reduced their bills immediately and improved air purity for sensitive packaging processes.

Case #2: Automotive Supplier

An automotive supplier near Nashville experienced frequent compressor overloads. Leak detection revealed leaks wasting 30% of system output. Repairs eliminated overloads, saving $15,000 annually and avoiding downtime.

Steps for Nashville Businesses to Get Started

Schedule a Leak Detection Audit – Have professionals inspect your system with ultrasonic tools.

Repair Identified Leaks – Replace fittings, hoses, and valves as needed.

Track Energy Bills – Compare usage before and after repairs to measure ROI.

Implement Ongoing Monitoring – Regular inspections keep leaks from creeping back.

Train Employees – Teach operators to recognize hissing sounds and pressure drops.

The Role of Preventative Maintenance

Leak detection works best as part of a larger preventative maintenance program. By combining leak audits with regular inspections of filters, dryers, and lubrication, facilities maximize savings and reliability.

Why Partner With Industrial Air Services

For Nashville businesses, choosing the right partner makes all the difference. Industrial Air Services offers:

Local expertise with a deep understanding of Tennessee industries.

Factory-trained technicians using advanced ultrasonic detection tools.

Fast response times from their La Vergne location.

Comprehensive solutions including repairs, upgrades, and preventative plans.

Final Thoughts

Compressed air leaks are one of the most overlooked costs in manufacturing — but also one of the easiest to fix. As this Nashville case study shows, leak detection can save tens of thousands of dollars each year, improve equipment reliability, and delay costly new investments.

For manufacturers and processors across Middle Tennessee, investing in professional leak detection is one of the smartest business decisions you can make. Don’t wait until energy bills rise or compressors wear out. The savings are already waiting to be captured.

Industrial Air Services – Serving Nashville, Knoxville & Chattanooga
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086