Compressed air is one of the most expensive utilities in industrial facilities, but it is often one of the least monitored. In fact, compressed air systems can account for 10–30% of a facility’s total electricity use, making inefficiencies costly and hard to ignore.
A compressed air audit provides the data your facility needs to uncover wasted energy, improve system efficiency, and reduce ongoing maintenance costs.
What Is a Compressed Air Audit?
A compressed air audit is a detailed analysis of your compressed air system using data logging equipment to measure your system’s performance. Over a specific monitoring period (usually one or two weeks) key metrics are captured, including:
This data reveals how your system actually performs during production, not just how it was designed to perform, which can inform your decision making as it relates to your compressed air system set-up, configuration, and the machine itself.
How Audit Data Can Drive Energy Savings
Undetected air leaks are one of the largest sources of energy waste in compressed air systems. Industry data shows that 20–40% of compressed air output can be lost to leaks. An air audit identifies leak severity and cost, allowing you to focus on repairs that deliver immediate energy savings. The sooner you find the leaks, the sooner they can be addressed and resolved!
Lower Pressure Leads to Lower Energy Bills
Running at higher pressure than necessary significantly increases energy consumption. Every 2 PSI (pounds per square inch) reduction in system pressure can lower energy use by approximately 1%. Air Audit data helps determine the lowest safe operating pressure for your specific application(s), reducing power draw while protecting production. Operating at the correct pressure level can lead to a reduction in operating/energy costs which can result in significant savings.
Right-Sizing Compressors and Controls
Many facilities operate with oversized compressors or inefficient control strategies, or both. Up to 30% of compressed air energy costs can be eliminated through proper system optimization. Audit results show whether equipment is oversized, poorly sequenced, or operating outside its efficient range, which can help your facility avoid unnecessary spending. Actions such as upgrading to a VSD compressor or adding a control panel may help your facility become more efficient.
Reducing Maintenance Costs and Equipment Wear
Inefficient systems don’t just waste energy, they accelerate wear and tear significantly.
Using air audit data to optimize your system can result in:
A well-optimized compressed air system can reduce maintenance costs by 10–25%!
Turning Audit Data into Smarter Decisions
A compressed air audit replaces assumptions with facts. Instead of reacting to failures, facilities can use audit data to:
This makes compressed air a controlled, measurable utility — not a hidden expense.
Why Now Is the Right Time for an Air Audit
With rising energy costs and increased pressure to improve efficiency, a compressed air audit is one of the most cost-effective ways to reduce operating expenses. Most facilities identify savings opportunities of 15–35% after completing an air audit. That’s real money saved year after year.
Book a Compressed Air Audit with NCA Ltd. and Start Saving Today!
If your facility is looking to reduce energy consumption, lower maintenance costs, and improve system reliability, a compressed air audit is the best place to start. Get in contact with NCA Ltd. today to book your compressed air audit. We’re ready when you are. The data tells the story and the savings follow!
Phone: 519-659-2691
Email: info@ncaltd.ca