The customer is a large, high-capacity automotive stamping facility that operates continuously, focused on precision engineering to produce top-quality components. Compressed air is essential for powering their hydraulic presses, automation systems, and auxiliary equipment. The company had an initiative to enhance operational efficiency and optimize air usage.
Due to the size of the stamping area in the automotive facility and the extensive distribution of compressed air system piping, leaks were difficult to identify during normal operations.
Rasmussen Air and Gas Energy expert technicians conducted a Phase 1 air leak audit to assess the current system efficiency.
Acoustic leak detection was used to survey the facility. Each leak was assigned a unique leak tag and documented with photographs of nearby equipment and zones to support maintenance repair efforts.
Acoustic leak detection uses ultrasonic sound generated by escaping compressed air to identify leaks that cannot be detected visually or audibly. This allows leaks to be identified while the system remains in operation and supports prioritization based on leak size and estimated cost impact.
The compressed air system audit identified over 80 individual leaks with a combined estimated leakage rate of 90 CFM. Using a compressor specific power of 30 kW per 100 CFM, the leaks represented approximately 27 kW of continuous demand.
At 8,760 operating hours per year, this equates to 236,520 kWh annually, or approximately $20,000 per year using an average industrial electricity rate.
The results showed that a relatively small number of higher-impact leaks accounted for the majority of total air loss. These findings supported the next steps toward a targeted, prioritized repair strategy.
Why Compressed Air Leaks Matter
Compressed air leaks not only waste energy, but they also increase compressor run time and add unnecessary load to the system. A properly maintained compressed air system should not leak more than 5–10% of the total supply. However, the reality is many facilities operate with leakage levels exceeding 30%. This excessive leakage increases system demand, contributes to pressure loss, and increases overall power consumption.
Air leaks directly cause a drop in pressure within the compressed air system. To ensure the necessary pressure is maintained at usage points, compressors are often set to operate at higher pressure levels. As a general guideline, for every 2 psi increase in system pressure, energy consumption rises by approximately 1%. This not only increases operating costs but also contributes to unnecessary wear on equipment.
Repairing compressed air leaks is generally inexpensive and can be done without altering production processes. Energy savings begin immediately after addressing leaks, making leak repair one of the quickest return opportunities in compressed air systems.
Fixing compressed air leaks reduces overall system demand and improves compressor efficiency. Common results include decreased energy use, shorter compressor run time, better pressure stability, and less strain on compressors and downstream equipment.
Most compressed air leaks originate from standard system components rather than major equipment failures. Common sources include fittings, quick disconnects, hoses, regulators, and valves. Poor maintenance, vibration, and repeated connection cycles increase the likelihood of leakage at these points.
Air leak audits apply to any industry that utilizes compressed air, such as automotive manufacturing, food processing and packaging, and general manufacturing. Facilities aiming for energy reduction and enhanced system reliability gain the most benefits.
If your operation is looking to optimize compressed air usage in your facility and reduce operating costs caused by inefficiencies, including air leaks, an audit is the first step.
Rasmussen Air & Gas Energy uses the latest technology to detect air leaks in your compressed air system. From there, we will create a plan of action to correct leaks and other identified inefficiencies and implement necessary repairs or replacements to get your compressed air equipment operating at peak performance.
Reach out to speak with a compressed air expert or schedule your audit today.