Compressed air is often the most expensive utility in a factory, and leaks typically waste a significant portion of what is generated. Because a leak runs 24/7 and is invisible, it is easy to ignore — but every leak forces the compressor to work harder, burning electricity to replace air that never does useful work. Finding and fixing leaks, then measuring flow and air quality, is one of the fastest energy-saving wins in any plant.
Why leaks cost so much
A compressor converts a large amount of electrical energy into a relatively small amount of useful compressed air; the rest becomes heat. So every cubic metre of air lost to a leak is expensive. Worse, leaks lower system pressure, which tempts operators to raise the set point — and a higher pressure increases energy use and the leak rate. Fixing leaks lets you run at lower pressure, compounding the savings.
How to find leaks
- Ultrasonic leak detection: a leak emits ultrasound you cannot hear; an ultrasonic detector pinpoints it, even in a noisy plant and without shutting down.
- Walk the system under load: survey during production, tag each leak, and prioritise by size.
- Repeat regularly: leaks return as fittings and hoses age — a one-off survey decays, a routine programme keeps savings locked in.
Measure what matters: flow, pressure, dew point
| Measurement | Why it matters |
|---|---|
| Flow / consumption | Shows total demand and where it goes; quantifies leak load and verifies savings after repairs. |
| Pressure | Reveals pressure drops and lets you run at the lowest pressure that does the job. |
| Dew point | Confirms the air is dry enough; wet air corrodes pipes, damages tools and ruins product. |
| Oil / particles | Verifies air quality against the ISO 8573 class your application requires. |
Build the business case
Measure flow before and after a leak-repair campaign and the saving is concrete kilowatt-hours — easy to put in front of management and to claim under energy-efficiency programmes. Continuous flow and dew-point monitoring then keeps the system honest and catches new problems early. This kind of measurement also supports ISO 50001 energy management.
Where to start
Survey for leaks with an ultrasonic detector, install flow and dew-point measurement on the main lines, fix the biggest leaks first, then lower the system pressure to the minimum the plant needs. Unitest Instruments supplies CS Instruments flow, pressure and dew-point measurement for compressed air, and can carry out a leak survey and air audit as a service.