The Cost-Saving Power of Compressed Air Audits

If your facility uses compressed air as part of its daily operations, you’re probably spending more than you should—sometimes a lot more. The reality is, most industrial air systems lose 20–30% of their energy to leaks, mismanagement, and inefficiencies. That’s where a compressed air audit can make all the difference.

At Industrial Air Services, we help manufacturers, processors, and commercial operators across Tennessee identify wasted energy, improve system performance, and lower utility bills through targeted compressed air audits. Whether you’re in Nashville, Knoxville, Chattanooga, or anywhere in between, these audits are one of the smartest investments you can make in your operation.

Let’s dive into how these audits work, what they uncover, and how they can lead to real-world savings—often in just weeks.

What Is a Compressed Air Audit?

A compressed air audit is a systematic analysis of your facility’s compressed air system, including compressors, piping, filtration, dryers, receivers, and end-use applications. The goal is simple: find where energy is being lost or misused and offer actionable recommendations to improve efficiency.

Audits typically include:

• Leak detection

• Pressure profiling

• Flow and CFM monitoring

• Air quality testing

• Demand-side analysis

• Load/unload cycle evaluation

• Power consumption tracking

• System layout and sizing review

A well-executed audit doesn’t just look at the compressor itself—it evaluates the entire air system, from generation to point-of-use.

Why Energy Loss Is So Common in Compressed Air Systems

Compressed air is often called the “fourth utility” in industrial environments, right behind electricity, gas, and water. But unlike those others, compressed air is notoriously inefficient if not maintained properly.

Here are a few reasons why:

• Leaks are invisible – You can’t hear or see most of them, especially in a loud shop. A single 1/8" leak can waste thousands of dollars per year.

• Oversized compressors – Running a system that's too big for your demand burns excess electricity.

• Poor piping layouts – Sharp turns, long runs, or bottlenecks reduce flow and increase pressure drops.

• Inadequate controls – Many facilities operate compressors at higher pressures than needed “just to be safe,” which results in wasted energy.

• Neglected maintenance – Dirty filters, clogged drains, and failing sensors all reduce system efficiency and shorten equipment life.

Without a regular audit, these problems can persist for years—costing your business far more than you might realize.

How Much Can You Save with an Audit?

The savings potential of a compressed air audit depends on your current usage and system health. That said, it’s not unusual to cut compressed air costs by 20–50%.

Here’s what you could see after implementing recommendations from a comprehensive audit:

• Reduced energy bills

• Decreased compressor runtime and wear

• Fewer breakdowns and unplanned shutdowns

• Extended equipment life

• Lower maintenance costs

• Improved air quality for sensitive applications

• Compliance with regulatory standards (ISO, FDA, etc.)

Many Tennessee businesses also qualify for utility rebates and incentives when they implement energy-saving improvements identified through an audit.

When Should You Schedule an Air Audit?

It’s easy to put off a compressed air audit until there’s a problem, but audits are most effective as preventive tools, not reactive ones. Consider scheduling one if:

• Your energy bills are higher than expected

• You haven’t audited your system in over a year

• You’ve recently expanded operations or added new equipment

• Your facility has pressure drop issues or equipment failures

• You’re planning a system upgrade or new compressor purchase

• You want to meet sustainability or energy efficiency goals

Even if everything seems fine, an audit can uncover hidden issues and unlock savings you didn’t know were there.

What Happens During an Audit?

At Industrial Air Services, our air audits are tailored to your facility’s needs and scale. A typical audit process looks like this:

1. Initial Consultation

We meet with your team to understand your production process, current system setup, and any challenges you’ve noticed. This helps us target key areas of concern.

2. On-Site System Evaluation

Our technicians walk the facility, inspecting compressors, filters, piping, and end-use equipment. We check for obvious issues like leaks, poor layouts, or underperforming components.

3. Data Logging and Monitoring

We install sensors to track pressure, flow, and power usage over a defined period—usually 7–10 days. This provides a real-world view of how your system performs under actual operating conditions.

4. Analysis and Reporting

We compile all data into a comprehensive report showing system inefficiencies, pressure profiles, load cycling, leak loss estimates, and potential cost savings.

5. Recommendations and Implementation

You’ll receive actionable suggestions to reduce waste and improve performance. We also offer installation, repairs, and equipment upgrades to help you put those ideas into practice.

Common Audit Discoveries

If you’ve never done an audit before, you might be surprised by what we find. Here are some typical issues uncovered in Tennessee facilities:

• Hidden leaks consuming 10–20% of total system capacity

• Running compressors at 120 psi when only 90 psi is needed

• Multiple compressors running simultaneously when one would suffice

• Wet or contaminated air due to failing dryers or clogged filters

• Poorly routed piping creating unnecessary pressure drops

Fixing these problems often pays for the audit and upgrades within a matter of months.

Serving Tennessee’s Industrial Backbone

Industrial Air Services has been performing compressed air audits across Tennessee for years, helping businesses lower costs, increase uptime, and improve air quality. We work with a wide range of industries, including:

• Food and beverage processing

• Automotive manufacturing

• Plastics and molding

• Pharmaceuticals and life sciences

• Metalworking and machining

• Chemical and petrochemical production

• Warehousing and logistics

Our coverage includes:

• Nashville

• Knoxville

• Chattanooga

• Murfreesboro

• Jackson

• Lebanon

• Columbia

• Cookeville

• Oak Ridge and surrounding areas

With fast response times and local expertise, we’re Tennessee’s trusted partner for compressed air system optimization.

Ready to Stop Wasting Money on Air?

Compressed air is one of the most expensive utilities in any facility—but it doesn’t have to be. A compressed air audit from Industrial Air Services can reveal where your system is leaking money and how to fix it.

If you want to reduce energy costs, extend the life of your equipment, and boost production reliability, let’s talk.

📞 Call us today at (615) 641-3100
📍 Visit us at 138 Bain Drive • LaVergne, TN 37086
💻 Or request an audit online at industrialairservice.com

Discover how much your compressed air system is really costing you—and how much you could be saving.