Techniquip Limited

Techniquip Ltd – The importance of monitoring compressed air

10-02-2026

Monitoring compressed air is vital for maintaining industrial efficiency, safety, and regulatory compliance. Often called the “fourth utility” alongside electricity, gas, and water, compressed air is one of the most expensive forms of energy, costing up to eight times more than electricity per unit delivered.

1. Operational Efficiency & Cost Savings

Leak Detection: Systems typically lose 20–30% (and up to 50%) of their volume to leaks. Monitoring tools like flow meters and ultrasonic detectors identify these losses, which can otherwise cost a single facility tens of thousands of pounds annually. Leak Detectors
Energy Management: Reducing system pressure by just 1 bar can decrease energy consumption by approximately 7%. Real-time data helps eliminate “artificial demand”—the practice of over-pressurising an entire system to satisfy a single high-pressure tool.
Optimised Sizing: Continuous data logging prevents the common mistake of over- or under-sizing replacement equipment by providing an accurate baseline of actual demand.

2. Equipment Reliability & Maintenance

Predictive Maintenance: Sensors for vibration, temperature, and oil levels detect subtle anomalies (like early-stage bearing wear) days or weeks before failure, shifting maintenance from reactive to proactive.
Extended Lifespan: Monitoring prevents issues like “rapid cycling” and overheating, which cause excessive wear on the compressor and the pneumatic tools it powers.
Downtime Prevention: Real-time alerts via systems like our DS 500 notify operators of out-of-spec readings immediately, allowing for repairs during scheduled stops rather than emergency shutdowns.

3. Air Quality & Compliance

Contaminant Control: For sensitive sectors like food, pharmaceuticals, and electronics, monitoring ensures air is free from oil, water vapour, and particulates. This prevents product spoilage and protects high-precision machinery.
Standard Adherence: Continuous monitoring validates compliance with international purity standards such as ISO 8573-1 and energy management standards like ISO 50001.
Safety: In industries requiring breathing air, regular testing (e.g., BS EN 12021 standards) is a legal requirement to ensure air is free from harmful contaminants like CO or CO2.

Key Metrics to Monitor

Parameter	Importance
Pressure (PSI/bar)	Detects leaks and prevents over-pressurisation.
Flow Rate (CFM)	Measures actual demand and identifies system waste.
Dew Point	Essential for preventing pipe corrosion and moisture in products.
Energy (kWh)	Tracks the “Specific Power” (efficiency) of the system.
Vibration/Temp	Acts as an early warning for mechanical component failure.