Tip 2: Find and Fix Compressed Air Leaks: The Fastest Way to Cut Costs

Compressed air is one of the most expensive utilities to produce in any factory. It takes a lot of electrical energy to compress and clean the air before it reaches your production lines. Yet in most facilities, a large portion of that effort is simply wasted through compressed air leaks.

According to the British Compressed Air Society (BCAS), even a well-maintained system can lose around 20% of its air through leaks. In some cases, that number can exceed 40%, costing thousands of pounds in wasted energy every year.

At Avelair, we see this problem time and time again. The good news is that leaks are one of the easiest and quickest energy savings to achieve, with paybacks often measured in weeks rather than years.

Why Leaks Are a Bigger Problem Than You Think

Leaks do not just waste energy. They also create issues across your entire compressed air system such as:

• Pressure fluctuations: Inconsistent pressure can slow down machines, cause product rejects, or even stop production lines.
• Increased running hours: Compressors must work harder to make up for lost air, using more electricity.
• Extra maintenance and wear: Overworked compressors and dryers fail faster and need more service.
• Noise: Escaping air adds constant background noise that contributes to fatigue and an unpleasant working environment.

A single 3mm hole in a pipe can cost over £600 a year in electricity. Multiply that across a site, and it is easy to see how leak prevention is one of the most profitable energy-saving projects available.

How to Find Compressed Air Leaks

Most leaks are small but continuous, so they are easy to miss during normal production hours. There are several ways to find them, ranging from simple manual checks to professional diagnostics.

1. Walk the site after hours

When the plant is quiet, walk around and listen for hissing sounds. This can reveal leaking joints, fittings, or connections that are otherwise hidden during busy operation.

2. Use an ultrasonic leak detector

At Avelair, we use ultrasonic detectors that pick up the high-frequency sound of escaping air. These tools allow us to pinpoint leak locations precisely, even while production is running.

3. Apply a leak detection spray or soap solution

If you suspect a specific joint or coupling is leaking, brushing a small amount of soapy water on it will reveal bubbles where air escapes.

4. Monitor system performance

Unexpected compressor cycling or an increase in off-load running time is often a sign that your leak rate is growing. Avelair can install permanent flow meters to help monitor this automatically.

Setting Up a Leak Management Programme

Fixing leaks once is good practice, but they will come back over time. That is why a leak management programme is essential for long-term savings.

Here is a simple framework we recommend to our customers:

1. Tag and record leaks: Use coloured tags or a digital record to log each leak on your site plan.
2. Prioritise repairs: Fix the largest or easiest leaks first to achieve quick wins.
3. Encourage staff reporting: Train operators to listen for and report leaks as part of routine checks.
4. Repair promptly: Do not allow “small” leaks to linger, as they can add up quickly.
5. Review regularly: Conduct a leak survey at least twice a year to stay on top of the issue.

If you do not have the resources in-house, Avelair can provide a comprehensive leak detection and repair service. This includes energy loss reports, prioritised repairs, and long-term monitoring.

The Benefits of Fixing Leaks

The results from leak reduction are immediate and measurable. Customers who work with us for leak audits often report:

• Lower energy bills: Each repaired leak reduces compressor workload and energy use.
• Improved pressure stability: Consistent pressure leads to smoother and more reliable production.
• Reduced maintenance costs: Compressors and dryers run fewer hours, extending service life.
• Quieter working environments: Eliminating hissing leaks makes the factory noticeably quieter.

You can often reduce your system’s generation pressure once leaks are fixed, which further cuts energy use. Every 1 bar reduction in pressure saves roughly 7% of compressor energy.

What Happens If You Do Not Address Leaks

Ignoring leaks does not only waste energy, it puts unnecessary strain on your entire system. Compressors run hotter, filters clog faster, and dryers work harder to keep up. Over time, this means higher maintenance costs, more downtime, and shorter equipment life.

In some cases, leaks can also pose a safety risk. A sudden pipe failure or coupling blowout could cause injury or damage nearby machinery. Regular inspections and maintenance protect both your energy spend and your team.

How Avelair Can Help

At Avelair, we have helped many manufacturers reduce wasted energy by identifying and repairing leaks efficiently. Our process includes:

• Full site surveys using advanced ultrasonic detectors
• Detailed energy loss reports that show estimated savings
• Professional repairs and system optimisation
• Ongoing leak management plans with repeat monitoring

We can also combine leak detection with data logging and efficiency audits to uncover further energy-saving opportunities across your compressed air system.

For more information on Tip 2: Find and Fix Compressed Air Leaks: The Fastest Way to Cut Costs talk to Avelair Compressed Air Solutions