Common Mistakes When Building a Compressed Air System

Purchasing or upgrading your facilities compressed air system is a very important decision that has implications for production, efficiency, and your bottom line. Oftentimes, potential buyers overlook certain factors or cut corners that can lead to a multitude of costly issues.

Whether you’re designing a new setup or upgrading an existing one, small mistakes can lead to major inefficiencies, higher operating costs, and unnecessary downtime.

Here are the most common mistakes and how to avoid them.

1. Undersizing (or Oversizing) the System

The mistake:
Choosing a compressor based only on current demand and/or choosing a unit that is too small or too large for your air needs.

• Undersized systems cause pressure drops and production issues
• Oversized systems waste energy and cycle inefficiently
• Demand shifts and your current configuration may no longer be appropriate

How to avoid it:

• Conduct a proper air audit that highlights flow, pressure, peaks. NCA can facilitate an air audit for your facility that can help garner this crucial information.
• Plan for growth without overcompensating
• Use variable speed where demand fluctuates

Entry-to-mid range systems are often well-served by the Quincy Compressor QGS series, which offers flexible sizing and configurations (tank mount, base mount, and integrated dryer packages) to match real demand.

2. Ignoring Air Quality Requirements

The mistake:
Not assessing air quality before selecting equipment and/or building a system without identifying air quality requirements.

Different applications demand different air purity levels:

• Food & beverage requires clean, dry air
• Manufacturing requires moisture and oil control
• Instrumentation requires ultra-dry air

How to avoid it:

• Define ISO air quality early
• Select proper dryers (refrigerated vs. desiccant)
• Size filtration correctly

Many modern compressor packages (like QGS with integrated dryers) simplify air quality compliance by bundling key components into one system, reducing the risk of under-specifying filtration.

3. Skipping/Overlooking Proper Drying and Filtration

The mistake:
Treating dryers and filters as optional. Incorrect dryer sizing and/or filters can lead to a number of issues in your system.

Moisture and contaminants can damage tools, corrode piping, and potentially impact end products/air quality to your pneumatic tools.

How to avoid it:

• Always include pre- and post-filtration
• Match dryer type to application (i.e., refrigerated, desiccant, cycling/non-cycling)
• Ensure filters are sized for system flow (CFM)

At NCA Ltd., our experts work with you to ensure you select the correct air dryer(s) and filters for your specific application.

4. Poor Piping Design

The mistake:
Undersized piping and/or inefficient layouts.

• Pressure drops
• Energy loss
• Poor distribution
• Inefficient compressor(s) and/or unnecessary cycling

How to avoid it:

• Establish a looped piping system
• Size for velocity and flow rate
• Minimize restrictions

Even the most efficient compressor will underperform if your piping system is working against. Do it right the first time to avoid issues down the road!

5. Not Including Enough Storage (Air Receivers)

The mistake:
Not prioritizing and/or undersizing air receivers is a crucial mistake that can create a multitude of problems.

Storage (air receivers) helps your system:

• Stabilize pressure
• Handle demand spikes
• Reduce compressor cycling

How to avoid it:

• Include wet and dry receivers where possible/applicable
• Place receivers strategically – have a plan for receiver placement

6. Ignoring Energy Efficiency

The mistake:
Focusing only on purchase price. Oftentimes, buyers focus on the sell price and not the long-term value a system can provide, especially as it relates to energy efficiency/energy savings.

Energy usage can account for up to 70–80% of lifecycle cost for your compressed air system!

How to avoid it:

• Use variable speed compressors where appropriate (QGSV, QGDV, QGV)
• Optimize system pressure
• Use zero-loss drains and efficient dryers
• Conduct an air audit to see where savings can be found

NCA Ltd. has helped procure companies over 1.5 million dollars to date with paid incentives and counting!

7. Overlooking Leak Detection

The mistake:
Ignoring leaks or treating them as minor. Leaks can silently cost you thousands a year.

Leaks can waste 20–30% of your system’s output!

How to avoid it:

• Implement routine leak detection
• Install/use ultrasonic leak detection tools like the Prosaris OL2
• Fix leaks proactively
• Ensure your maintenance/PM program is focused on identifying and addressing leaks

8. Poor Equipment Placement

The mistake:
Installing your compressed air system in hot, dirty, or tight spaces.

• Heat reduces efficiency and lifespan
• Dirt increases maintenance + lifecycle of your filters
• Poor access complicates service and may lead to avoidance of certain maintenance tasks
• Heat and contaminants make your system work harder – shortening its lifespan

How to avoid it:

• Ensure ventilation and clean intake air
• Allow maintenance space
• Keep ambient conditions controlled

Many Quincy rotary screw compressors are designed with quiet enclosures and service-friendly layouts, allowing installation closer to production while maintaining accessibility.

9. No Redundancy or Backup Plan

The mistake:
Relying on a single compressor/not having a redundancy plan in place for when issues arise.

Downtime will lead to lost revenue and increased maintenance costs. Many headaches can be avoided by ensuring you have a redundancy plan in place for when problems arise.

How to avoid it:

• Use multiple compressors (load sharing)
• Plan maintenance without shutdown
• Have a PM/maintenance schedule in place

Compressor systems like the QGD can be networked together, allowing multiple units to operate as a coordinated system for reliability and efficiency.

10. Lack of Monitoring and Controls

The mistake:
Operating your system without visibility and controls will lead to problems if not addressed appropriately.

You can’t optimize what you don’t measure!

How to avoid it:

• Install system controls like an Air Leader or Air Logic2.
• Monitor pressure, flow, and energy
• Use smart sequencing
• Install a leak detection system

Advanced controllers (like Airlogic2) allow scheduling, monitoring, and system optimization—helping reduce waste and improve uptime.

In Summary

A compressed air system is a long-term investment and the difference between a good system and a great one comes down to design decisions made early and with purpose/expertise. Making the right decisions at the outset will extend equipment life and protect your investment.

By avoiding the common mistakes mentioned above and selecting proven equipment, you can build a system that is efficient and reliable. Get in touch with NCA today to build a system you can feel confident with now and in the future.

Phone: 519-659-2691
Email: info@ncaltd.ca