The Real Cost of Running Your Compressor at Higher-Than-Necessary Pressure
When pressure problems show up in a facility, the most common reaction is simple: turn it up.
Need more airflow at the far end of the plant? Increase pressure.
Tools feel weak during peak demand? Increase pressure.
Operators complain? Increase pressure.
Across manufacturing plants and industrial facilities in Nashville, Knoxville, Chattanooga, and throughout Central and East Tennessee, raising system pressure is one of the most common — and most expensive — “fixes” we see.
The problem is, increasing pressure rarely solves the root cause. It simply increases operating cost.
Every PSI Costs You Money
Compressed air energy consumption rises as pressure increases.
Even small increases:
Raise motor load
Increase electrical consumption
Amplify leak losses
Add stress to system components
That extra pressure might stabilize tools temporarily, but it increases your utility bill every single hour the compressor runs.
Higher Pressure Makes Leaks Worse
Leaks waste more air at higher pressure.
If your facility already has leak losses — and most do — increasing system pressure:
Pushes more air through every leak
Forces compressors to run longer
Increases energy waste
It becomes a compounding problem.
Over-Pressurizing Stresses Equipment
Compressed air components are rated for specific pressure ranges.
When systems operate higher than necessary:
Regulators wear faster
Seals and fittings degrade sooner
Actuators experience increased stress
Maintenance frequency rises
Over time, higher pressure accelerates wear across the entire system.
Pressure Drop Is Often the Real Problem
In many facilities, the reason pressure was increased in the first place is pressure drop.
Common causes include:
Undersized piping
Clogged filters
Inadequate air storage
Excessive elbows and restrictions
Moisture and corrosion buildup
Raising pressure hides these issues instead of correcting them.
Higher Pressure Doesn’t Improve Efficiency
There’s a common misconception that “more pressure equals more performance.”
In reality:
Tools perform best at designed operating pressure
Excess pressure doesn’t increase efficiency
Over-pressurizing may reduce tool life
Correct pressure at the point of use is more important than higher pressure at the compressor.
Compressors Work Harder Than Necessary
When pressure is increased:
Load time increases
Unload cycles may increase
Heat generation rises
Oil degradation accelerates
Operating hotter and longer reduces compressor lifespan.
The Long-Term Financial Impact
Over months and years, running higher-than-necessary pressure results in:
Higher energy bills
Increased maintenance costs
Shortened equipment life
Greater downtime risk
Many facilities don’t realize how much of their compressed air budget is tied directly to pressure settings.
The Smarter Approach: Fix the Root Cause
Instead of raising pressure, investigate:
Leak losses
Piping restrictions
Storage capacity
Control settings
Filter and dryer performance
Correcting the underlying issue often allows system pressure to be reduced — improving both efficiency and reliability.
Pressure Optimization Delivers Fast ROI
Reducing system pressure to the minimum effective level:
Lowers energy consumption immediately
Reduces leak waste
Stabilizes system operation
Extends equipment life
It’s one of the fastest ways to improve compressed air efficiency without major capital investment.
Local Expertise You Can Rely On
At Industrial Air Services, we help facilities across Nashville, Knoxville, Chattanooga, and surrounding Central and East Tennessee evaluate system pressure, identify root causes of instability, and optimize performance without unnecessary equipment replacement.
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
