Why Air System Audits Improve Efficiency and Reduce Operating Costs
Most facilities don’t realize how much money their compressed air system is wasting until they see the data. Between leaks, pressure drops, oversized compressors, undersized dryers, and poor piping layouts, it’s common for plants to waste 20–50% of their compressed air energy without knowing it.
That’s where an air system audit comes in. A proper audit gives you a detailed look at how your system actually performs — not how it’s supposed to perform on paper.
At Industrial Air Services, we perform full compressed air audits across Nashville, Knoxville, and Chattanooga, helping facilities cut energy costs, improve performance, and extend the life of their equipment. Here’s why audits matter and why they pay for themselves faster than most upgrades.
1. You Can’t Fix What You Can’t See
Compressed air problems are often invisible. You can’t see energy waste. You can’t see pressure drop. You can’t see leaks behind walls or above ceiling lines. And you can’t see inefficiencies inside the compressor without the right tools.
An audit shows:
How much air you use
When you use it
Where you lose it
How efficiently your system runs
Whether your compressor is sized correctly
Where moisture and oil are getting in
How your piping design is affecting pressure
With real data, you can make smart decisions — not guesses.
2. Audits Reveal Costly Air Leaks
Every plant has leaks. The question is how many — and how big.
A single 1/8-inch leak can cost $1,200 to $2,000 per year in wasted energy.
An audit uses ultrasonic leak detection to find leaks that:
Aren’t loud enough to hear
Are hidden behind machinery
Occur in elevated lines
Only appear under certain loads
Most facilities that go through a full audit are shocked by how much air they lose to leaks alone.
3. Pressure Mapping Shows Where Performance Drops
Many systems run at higher pressure than needed just to overcome pressure drop. But that approach wastes a tremendous amount of energy.
An audit measures pressure at:
The compressor
The header
The far-end drops
Critical machines
Tools and workstations
If you lose 10–20 PSI between the compressor and the point of use, you’re burning money.
Fixing pressure drop almost always produces immediate savings.
4. Audits Identify Inefficient or Incorrectly Sized Equipment
Many facilities run compressors that are either:
Too big (wasting energy)
Too small (straining to keep up)
Poorly matched to the dryer or filters
Operated inefficiently
An audit compares actual demand against compressor output so we can determine the ideal setup.
This often leads to:
Switching to a VSD compressor
Adding storage
Retuning controls
Replacing undersized dryers or filters
Eliminating unnecessary equipment cycling
Just correcting sizing issues can save thousands each year.
5. Energy Profiles Show When You’re Wasting Power
Most facilities waste the most air during:
Shift changes
Lunch breaks
Idle hours
Nights and weekends
During an audit, data loggers track system performance across multiple days. This reveals:
Wasteful baseline load
Inefficient cycling
Compressors running when they shouldn’t be
Unexpected spikes in consumption
Often, slight adjustments to controls or scheduling cut energy use dramatically.
6. Auditor Tools Measure What You Can’t
A proper air system audit uses:
Flow meters
Pressure sensors
Data loggers
Ultrasonic leak detectors
Dew point monitors
Thermal imaging (when needed)
These tools provide a detailed picture of your system’s performance — far beyond what you can observe manually.
7. Audits Improve Air Quality
Moisture and oil in lines can ruin tools, contaminate products, and damage valves.
Audits often uncover:
Dryer performance issues
Undersized dryers
Failed condensate drains
Clogged filters
Piping low spots with water buildup
Fixing these issues protects both your production and your equipment.
8. Audits Extend Compressor Life
A struggling compressor is an expensive compressor. When inefficiencies stack up — leaks, pressure drop, heat, moisture — the compressor runs harder and longer than it should.
After an audit, most systems:
Run cooler
Cycle less
Maintain steadier pressure
Produce cleaner air
Require fewer emergency repairs
A healthier system means less downtime and lower cost of ownership.
9. Audits Highlight Low-Cost Improvements With Big Impact
Most efficiency gains come from simple fixes:
Repairing leaks
Cleaning coolers
Adjusting controls
Replacing drains
Redesigning piping drops
Upgrading filters
Adding a second receiver tank
You don’t have to buy new equipment to save money — you just need to optimize what you have.
10. The Audit Report Gives You a Plan — Not Guesswork
At the end of an audit, you receive a clear, documented roadmap that outlines:
Current system performance
Key issues detected
Cost of inefficiencies
Recommended upgrades
Expected energy savings
Estimated payback period
This report makes it easy to budget and plan improvements the right way.
A Better Air System Starts With Data
Air system audits take the mystery out of compressed air performance. When you know what’s happening inside your system, you can eliminate waste, protect your equipment, and cut energy costs — often faster than you think.
If you're curious how much your facility could save, we’re here to run the numbers.
Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing full compressed air audits, leak detection, system optimization, and energy-saving solutions.
📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com
