In many facilities, the compressed air system accounts for upwards of 30% of total energy consumption, and inefficiencies often go unnoticed until the costs begin to stack up.
As we head into 2026, rising energy prices and the push toward more efficient operations make it more important than ever to understand how your system uses power and where you can quickly make improvements to save energy and in turn, money.
Below, we break down what affects compressor energy usage and the most effective strategies to reduce energy usage in your facility.
What Drives Compressor Energy Usage?
The higher the pressure (PSI), the harder your compressor system works. Even a 2 psi increase can raise energy consumption by 1%. Many plants operate at higher pressures than necessary, usually to compensate for air leaks or improper system design.
Leaks are one of the biggest hidden energy drain. A single 1/8” hole in your system can waste thousands of dollars per year in electricity. Most facilities run with leak rates of around 20–30%, which means nearly a third of produced air never gets used.
How your compressor cycles affects your energy usage. Standard fixed-speed compressors draw significant power even when they’re unloaded, which leads to wasted energy, especially during lower-demand times.
Dirty filters force the system to work harder, increasing pressure drops and energy consumption. Moisture issues can also reduce efficiency, especially during the winter months.
Sometimes the system is simply mismatched to the application. An oversized compressor uses more energy than required, while aging units lose efficiency the longer they’ve been in service.
How to Reduce Your Compressor Energy Usage in 2026 and beyond
An air audit identifies leaks, pressure drops/losses, and equipment issues. At NCA, our team can perform a full system evaluation to show exactly where improvements will have the biggest impact. NCA also offers leak detection management solutions that enable the user to effectively manage this process to ensure leaks are properly identified and mitigated if/when they arise.
Leak detection is one of the fastest, most cost-effective ways to reduce energy costs. Regular inspections and/or leak detection management systems prevent small issues from turning into major losses.
By lowering your system pressure to the minimum required level:
A properly calibrated system can cut your utility bill significantly by ensuring your system is not working harder than it needs too. The team at NCA are experts at optimizing system pressure to ensure you are achieving your desired PSI/CFM while being as efficient as possible.
VSD compressors, like the Quincy QGV series, only produce the air you need, no more, no less.
This can reduce energy usage by up to 35% and eliminate inefficient load/unload cycling. Contact a NCA sales representative today to learn more about VSD options that may be a fit for your facility/application.
Changing filters on schedule, maintaining air dryers, and ensuring proper condensate management all reduce pressure drops and boost your efficiency. Ensuring you have an effective preventative maintenance program that includes the aforementioned steps can help your facility work towards efficiency and cost reduction.
Compressors generate significant amounts of heat. A heat recovery system repurposes this wasted heat for space heating or water heating, offering substantial savings.
Preventative maintenance (PM) ensures:
A well-maintained compressor always consumes less energy. A PM program is essential to protect your investment and ensure that your system is always working at peak efficiency. NCA works with each client to craft a tailored PM program that works with their budget and compressor system.
Why This Matters for 2026
Energy efficiency isn’t just about saving money (although those savings can be significant). It also helps facilities:
With rising utility costs and increased demand on production systems, now is the best time to invest in smarter air management. Set your team/facility up for a successful 2026 by following these steps and start saving today.
How NCA Ltd. Can Help
NCA Ltd. provides:
If you want to lower energy costs in 2026 and beyond, we can help you identify where to start and provide the solutions to keep your system running efficiently all year long.
Get in touch with us today!
Phone: 519-659-2691
Email: info@ncaltd.ca