Ask the Experts: How to achieve compressed air system efficiency gains

Key takeaways

Leak detection and repair programs can cut compressed air waste by up to 50%, saving significant energy and costs.
Lowering system pressure by just 2 psi reduces energy use 1% and lessens leaks, delivering quick, low-cost efficiency gains.
System audits, smart controls, and data monitoring reveal inefficiencies and unlock 10–30% energy savings with strong ROI.

In this Ask the Experts feature, which runs regularly in Plant Services, expert instructors from the Compressed Air Challenge (CAC) tackle questions on compressed air systems and associated technology.

The Compressed Air Challenge, an educational foundation administered by the Compressed Air & Gas Institute, is a voluntary collaboration of industrial end-users; manufacturers, distributors, and their associations; trade organizations; consultants; state research and development agencies; energy efficiency organizations; and utilities. The CAC has one purpose in mind—helping facilities enjoy the benefits of improved performance of your compressed air system.

This month's question: What would your compressed air improvement advice be to a plant manager faced with business uncertainty and shrinking budgets? Can you suggest the top three compressed air improvement actions they should take to reduce their operating costs?

1. Reducing Leaks and Misuse

Ron Marshall (Winnipeg, MB, L1&2 Trainer): Leaks can waste 20 to 40 percent of compressed air in unmanaged systems. Simple methods like soap bubble testing or using a basic ultrasonic leak detector can uncover major losses. Engaging operators in spotting leaks during regular rounds is also effective and free.

Paul Shaw (Berlin, CT, L1&2 Trainer): A major opportunity lies in identifying and fixing air leaks. Leaks can consume a significant amount of a system’s output, and in poorly maintained systems, even more. Using an ultrasonic leak detector to audit your system—especially the last 30 feet of hose drops and tool connections—can uncover hidden losses.

Detection is just the start; fixing the leaks is what delivers savings. Making leak detection and repair a scheduled maintenance task can keep systems running efficiently and reduce energy waste by up to 50%.

Also, eliminating inappropriate uses of compressed air, such as using it for sweeping, cooling, or part ejection, can lead to substantial reductions in demand. These applications are often better served by electric fans, blowers, or other alternatives. A plant-wide usage audit can highlight where compressed air is being misapplied. Combined with training staff to recognize and avoid wasteful practices, this strategy can cut demand by 5-15% or more.

Paul Maguire (Natick MA, L1 Trainer): I often recommend as a first step to eliminate air leaks, which account for significant compressed air loss in many facilities. A leak detection and repair (LDAR) program using ultrasonic leak detectors can recover thousands of dollars in wasted energy annually.

2. Lowering System Pressure

Ron Marshall: Lowering system pressure is another easy win. Many systems run 10-20 psi higher than needed, and reducing pressure by just 2 psi can cut energy use by 1%. A quick pressure mapping exercise helps identify how low you can go without affecting performance. And reducing pressure also reduces leaks, about 1% less flow for every 1 psi in pressure reduction.

Paul Shaw: One of the quickest wins is to lower system pressure. To do this safely, first assess the pressure needs of your equipment, then reduce compressor setpoints in small steps while watching for performance issues. Clearing up restrictions like clogged filters or undersized piping ensures you can reduce pressure without causing problems. Many plants save 3-10% of their compressor energy costs this way with even greater savings possible if a lightly loaded compressor can be turned off entirely.

Paul Maguire: Lowering pressure from 110 to 100 psi could save up to $10,000 per year in a mid-sized plant. Consider this as a primary step to save costs.

3. Training and Workforce Education

Ron Marshall: Staff training offers a strong return. The Compressed Air Challenge’s Fundamentals and Advanced seminars teach practical, energy-saving strategies. A well-trained team avoids mistakes like overusing backup compressors or misusing air. The training also supports professional growth through CAGI certification pathways. Register here.

Kyle Peltier (Rock Hill, SC, L1 Trainer): Train your staff. No one is going to realize something is off if they do not know what they are looking at, and they don’t know what they don’t know until they take a little formal training. Consider having several people from your maintenance team, operations team, and management take at least a basic compressed air systems class such as the Compressed Air Challenge level 1 course.

4. System Measurement, Audits, and Controls

Kyle Peltier: Without a doubt if the plant is not measuring power to each compressor, air flow from the compressor room, and pressure at multiple points across the plant that should be implemented immediately! It is very inexpensive and can quickly highlight areas of concern that can be improved to save on operating expenses.

Let’s be honest, there are very few true compressed air system experts out there, and odds are none of them have reviewed your specific plant. A full compressed air system audit can not only save you money by highlighting adjustments that reduce compressed air waste, but can also be used in many cases to get rebates from power companies to support updates and upgrades to your system to reduce power consumption.

Jan Hoetzel (Grand Rapids, MI, L1 Trainer): Three proven steps can quickly reduce costs: First, gather real-time performance data to simulate system behavior under optimized control—revealing exactly where energy is lost. Second, improve the demand side by fixing leaks, trimming pressure, and reducing artificial demand—often cutting usage by 10-30% with minimal investment. Finally, install a smart master controller to automatically manage compressor operation based on real-time demand, stabilizing pressure while minimizing runtime and energy waste.

While these steps bring immediate operational benefits, their long-term financial impact is even more compelling. Smart control systems typically pay for themselves within 12-18 months, but a deeper analysis using Net Present Value (NPV) shows the real return. By projecting energy and maintenance savings over a 10-15 year period, NPV turns a short-term expense into a long-term asset, boosting profitability and operational stability for years to come. Unlike major mechanical overhauls, these control-layer improvements enhance existing infrastructure, lower total cost of ownership, and scale with your needs.

Paul Maguire: One final recommendation, consider upgrading to variable speed drive (VSD) compressors if you need a new compressor. These systems adjust output based on real-time demand, offering energy savings of 25-35% compared to fixed-speed units. To guide and justify these improvements, data monitoring tools like flowmeters and pressure sensors can help managers identify inefficiencies and calculate ROI, turning compressed air from a hidden cost into a strategic opportunity.

Juan Londono (Winnipeg, MB, L1 Trainer): Configuring the air compressors control to match the system's demand profile efficiently will substantially reduce the energy consumption by minimizing unloaded run time, preventing simultaneous operation of multiple compressors at partial load, and ensuring that the most energy efficient compressor is loaded or prioritized in the control chain.

Ron Marshall: Consider having an auditor take a close look at your compressor controls. Quite often built in energy management features are not activated and could save thousands of dollars in unloaded compressor run time. Commonly the auto feature of compressors is not activated, resulting in wasted energy consumption.

5. Heat Recovery

Ron Marshall: Recovering heat from industrial air compressors offers significant financial benefits by turning wasted energy into usable heat. Since up to 90% of the electrical energy used by a compressor is converted into heat, capturing and reusing this energy—for space heating, water heating, or process heat—can substantially reduce fuel or electricity costs. Facilities that implement heat recovery systems often see a fast return on investment, with some achieving full payback in under a year. This not only lowers utility bills but also improves overall energy efficiency and supports sustainability goals.