Why Undersized Compressed Air Piping Is Costing Your Facility Money
Most facilities focus on the compressor when performance issues show up. But in many cases, the real problem isn’t the machine making the air — it’s the piping delivering it.
Undersized compressed air piping is one of the most common and most expensive design mistakes we see across manufacturing plants, fabrication shops, automotive facilities, and production floors in Nashville, Knoxville, Chattanooga, and throughout Central and East Tennessee.
Air is being produced. The compressor is running. But the piping system is quietly restricting airflow — and the costs add up fast.
Compressed Air Is Only as Good as Its Delivery System
A compressor can generate plenty of capacity, but if the piping can’t move that air efficiently, performance suffers.
Undersized piping:
Restricts airflow
Creates pressure drop
Forces compressors to work harder
Increases energy consumption
Causes inconsistent tool performance
It’s like installing a high-powered pump but feeding it through a garden hose.
Pressure Drop Is the First Warning Sign
When piping is too small, pressure loss increases as air travels through the system.
You may notice:
Tools slowing during peak demand
Operators turning up regulators
System pressure being increased at the compressor
Complaints from workstations farthest from the compressor
Instead of fixing the restriction, many facilities increase system pressure — which raises energy costs and stresses the entire system.
Long Pipe Runs Make the Problem Worse
Even if pipe diameter is technically adequate near the compressor, long runs amplify restrictions.
Common layout issues include:
Single main lines feeding the entire facility
Excessive elbows and tees
Dead-end piping
No looped distribution system
Every restriction increases friction loss. Over distance, that loss becomes significant.
Undersized Piping Drives Up Energy Costs
Compressed air is already one of the most expensive utilities in a facility.
When piping is too small:
Compressors run longer
System pressure must be set higher
Leaks waste more air
Operating temperatures increase
Even a small increase in operating pressure can significantly raise energy usage.
Many facilities are paying more every month simply because their piping system can’t move air efficiently.
Growth Makes Old Piping Designs Fail
Piping systems that once worked fine may struggle after expansion.
If your facility has:
Added new tools
Installed new equipment
Extended shifts
Increased production
…your original piping design may no longer be sufficient.
Undersized piping often becomes a bottleneck as operations grow.
Undersized Piping Causes Short Cycling
Inadequate airflow can also contribute to compressor short cycling.
As pressure drops quickly during demand spikes:
The compressor starts more often
Load/unload cycles increase
Mechanical wear accelerates
This creates higher maintenance costs and reduces equipment life.
Moisture and Corrosion Make Restrictions Worse
Small piping isn’t the only issue. Over time, corrosion and debris inside piping reduce effective diameter even further.
Moisture buildup can:
Roughen pipe interiors
Create scale and rust
Increase airflow resistance
A pipe that was marginally sized when new may become highly restrictive after years of internal corrosion.
Bigger Isn’t Always Complicated
Correcting piping issues doesn’t always require a full system replacement.
Solutions may include:
Increasing main line diameter
Adding looped distribution
Installing additional drops
Improving airflow balance
Repositioning storage
Often, strategic upgrades deliver significant improvements without major disruption.
Signs Your Piping May Be Undersized
Common red flags include:
Pressure drops during simultaneous tool use
Inconsistent air delivery at distant workstations
Frequent regulator adjustments
Compressors running longer than expected
Rising energy bills without increased production
If these symptoms sound familiar, piping should be evaluated before replacing compressors.
Piping Is a Long-Term Investment
Unlike compressors, piping systems often remain in place for decades. Getting the design right protects performance for years.
Well-designed piping:
Minimizes pressure drop
Reduces energy costs
Stabilizes airflow
Supports future expansion
Extends compressor life
It’s one of the smartest investments a facility can make.
Local Expertise Matters
At Industrial Air Services, we help facilities across Nashville, Knoxville, Chattanooga, and surrounding Central and East Tennessee evaluate compressed air piping systems and identify restrictions that drive up costs. From airflow analysis to strategic piping upgrades, our focus is improving efficiency without unnecessary equipment replacement.
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
