01992 238 339
Account
Get a Quote
Log in

Where Industrial Sites Waste Compressed Air Energy

Air Energy Engineer Spotlight: Insights from a Technical Support Engineer

Where Compressed Air Systems Waste Energy

And How to Reduce It
Insights from Chris, Technical Support Engineer
Compressed air is one of the most widely used utilities in industrial sites – but also one of the most energy-intensive. We asked Chris, one of our engineers, about the most common issues he sees on site, and where energy is typically being lost in compressed air systems.

Running a compressor outside its optimal range is like trying to drive your car in first gear instead of fifth. It’s inefficient and wastes energy

One of the most common problems we see is compressors that aren’t correctly sized for the site’s demand. A compressor should ideally operate at around 70–80% of its capacity for efficient operation.

If the compressor is too small, it ends up running constantly in an attempt to keep up with demand. That can lead to overheating, reduced efficiency and issues like oil carry-over into the compressed air system.

On the other hand, if the compressor is too large, it will spend too much time starting and stopping rather than running in a stable operating range. That constant cycling wastes energy and increases wear on the equipment.

Running a compressor outside its optimal range is like trying to drive your car in first gear instead of fifth – it’s inefficient and wastes energy. Many people don’t realise how much energy compressed air systems actually use.

In many factories the compressor is one of the single largest consumers of electricity, so ensuring the system is correctly sized for the application can make a significant difference to energy efficiency and operating costs.

Running a compressor outside its optimal range is like trying to drive your car in first gear instead of fifth – it’s inefficient and wastes energy.

Leaks are extremely common in industrial compressed air systems. Across industry it’s often estimated that 20–30% of compressed air output can be lost through leaks, particularly in older systems or facilities that haven’t had a recent survey.

The challenge is that many leaks are inaudible. Small leaks can’t be heard during normal operation, especially in busy factory environments. During leak audits we often identify multiple smaller leaks across a site – individually they may only cost hundreds of pounds per year, but collectively the losses quickly add up.

Where leaks become more significant is when they are audible. If you can hear a compressed air leak, it’s usually already costing £400–£500 per year in wasted energy. Across a site, just a handful of audible leaks can easily reach £2,000–£2,500 per year or more, and that’s typically only the visible part of the problem.

While leak detection is often the quickest way to identify immediate losses, it’s usually part of a wider system issue. Compressor sizing, pressure settings, pipework design and system controls all play a role in overall efficiency.

In practice, the biggest savings tend to come from looking at the compressed air system as a whole. not just individual leaks.

Leak detection is often the starting point – but the biggest savings come from looking at the compressed air system as a whole.

In most cases, the fastest improvements come from two areas: fixing leaks and ensuring the compressor system is operating correctly for the site’s demand.

A structured leak detection survey can quickly identify losses that aren’t visible or audible during normal operation, allowing maintenance teams to prioritise the most significant issues.

At the same time, it’s important to review whether the compressor system itself is operating efficiently. That includes checking the sizing of the compressor, reviewing system pressure settings, and ensuring the equipment is running within its most efficient operating range.

Small improvements in these areas can have a noticeable impact on overall system efficiency, helping reduce electricity consumption and extend the life of the equipment.

Concerned about wasted compressed air energy?

Talk to one of our engineers about a compressed air audit or leak detection survey

Talk to an expert

Air Energy Marks World Environment Day with Solar Investment and New Wasted Air Energy Calculator

To mark World Environment Day 2026, Air Energy is highlighting practical action on energy efficiency both within our own operations and through the work we do with customers. While this is an important step for Air Energy, our wider environmental contribution is also connected to the work we do every day.Compressed air is essential across…
Read article Air Energy Marks World Environment Day with Solar Investment and New Wasted Air Energy Calculator

Industrial Air Insights

Practical guidance on reliability, efficiency and compliance for compressed air, vacuum and nitrogen systems.

We use cookies to ensure that we give you the best experience on our website.

ACCEPT MORE INFO
You were not leaving your cart just like that, right?

Did you mean to abandon your order?

Enter your details below to save your shopping cart for later.