Why Fix Compressed Air Leaks?

On average most manufacturing plants waste 27% of their compressed air capacity servicing leaks (Energy Efficiency Best Practice Guide Compressed Air Systems, Sustainability Victoria, 2009, p10). 

This puts increased load on the plant's air compressors, and reduces the capacity available to the plant. It can also lead to ill-informed management decisions, like buying a new compressor unnecessarily, and wasting money on energy when you don't need to.

Although implementing a leak fix program can be one of the most cost-effective risk mitigation and energy savings opportunities you have available, we know from our quantitative reviews that many of these leak management programs are not effective for the following reasons:

  • Leak loss is not measured and vastly inaccurate estimates are made of energy savings, making payback look much more attractive than it is. If you don’t accurately measure leak loss how do you know if you should be fixing leaks or not, or if you have fixed the leaks at all? Why invest money with such high uncertainty?

  • Ultrasonic leak detection is conducted ineffectively and many substantial leaks are not identified.

  • Where companies elect to fix the leaks themselves, the repairs take too long as companies generally don’t have the time or resources to rectify the leaks in a timely fashion, resulting in the business losing thousands of dollars per month in unnecessary energy costs.

Leak fix should not be a gimmick
 - it should be a robust activity that has
genuine benefits and proven financial returns.

Out Performers is Australia’s leading
compressed air solution provider.