Compressed air leaks are one of the most common causes of wasted electricity in factories, workshops and production facilities. Many businesses do not realise how much money is lost when a compressor keeps running to replace air that is escaping through leaks.
At Airecare, we often find that small leaks in the compressed air system can cause the compressor to run longer, load more often and use more electricity than necessary.
Why Air Leaks Are a Problem
A compressed air system is designed to supply air to tools, machines and production equipment. When there are leaks in the pipework, hoses, fittings, valves, couplings or drains, the compressor must work harder to maintain pressure.
This means the customer may be paying for electricity that is not being used for production.
Common Places Where Air Leaks Are Found
Air leaks are often found in:
- Quick couplers
- Flexible hoses
- Threaded fittings
- Old ball valves
- Auto drains
- Filter housings
- Regulator assemblies
- Pipe joints
- Damaged air lines
- Equipment left open when not in use
Even a small leak can become expensive if it runs all day and night.
Signs That Your Factory May Have Air Leaks
You may have compressed air leaks if you notice:
- The compressor runs when production is stopped
- The compressor loads and unloads too often
- Pressure drops quickly when the compressor stops
- Air can be heard escaping around the factory
- Electricity usage is higher than expected
- The compressor struggles to maintain pressure
- Operators increase pressure to compensate for low air supply
Increasing the pressure is not always the correct solution. In many cases, the real problem is air loss through leaks.
Why Leaks Increase Electricity Costs
When air escapes from the system, the compressor must replace that lost air. This increases running hours and electricity consumption.
A leaking system can also cause the compressor to run hotter, increase service wear and reduce the life of filters, oil and other components.
Fixing leaks can reduce wasted energy, improve system pressure and help the compressor operate more efficiently.
What Airecare Recommends
Airecare recommends regular compressed air leak inspections, especially for factories with high electricity costs or compressors that run for long hours.
A proper leak inspection should include:
- Checking pipework and fittings
- Inspecting drains and filters
- Listening for air leaks during shutdown
- Checking pressure drop when production is off
- Reviewing compressor run and load hours
- Checking whether the compressor is correctly sized
- Identifying areas where pressure can be reduced
Can a VSD Compressor Help?
A VSD compressor can help reduce electricity usage in the right application, especially where air demand changes during the day. However, a VSD should not be quoted blindly.
Before recommending a VSD conversion or new VSD compressor, Airecare recommends checking the air demand, leaks, operating pressure, receiver capacity and compressor load pattern.
In many cases, fixing air leaks first can reduce the size of compressor required and improve the payback period of a VSD system.
Need Help Reducing Compressed Air Electricity Costs?
Airecare assists with compressed air leak inspections, compressor servicing, air dryers, filtration, VSD feasibility checks and compressed air system improvements in Durban and across KZN.
If your compressor is running longer than expected or your electricity cost is high, contact Airecare for a compressed air system inspection.
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