For many Iowa manufacturers and industrial businesses, compressed air is one of the most expensive utilities in their facility. Unfortunately, it is also one of the most wasted. 

What is the cost of a compressed air leak?

Many facilities are surprised to learn that 20 to 30 percent of the compressed air a system produces can be lost through leaks.

One small leak in one hose could cost your company $75 annually. Larger leaks could cost upwards of $1,415 annually (hum…what else could that money go towards?). 

In short, any compressed air leak can significantly increase energy costs, reduce system performance, and force compressors to work harder than necessary.

How to detect a compressed air leak? 

The larger the leak, the easier it is to identify. In one case, an assessor felt high-pressure air blowing on his leg when walking by a workbench. The smaller leaks are trickier to identify. If you notice:

• The system is working poorly, 
• Your energy usage has continued to increase over time (with no other explanation), or
• You notice a sudden spike in costs, 

a leak may be the culprit. 

When Iowa Waste Reduction Center (IWRC) specialists conduct a comprehensive evaluation of a business's compressed air system, we use state-of-the-art ultrasonic leak detection equipment to locate leaks that are often impossible to notice during normal plant operations. 

What happens after a leak is identified? 

Now it is time to fix the leaks! In many cases, repairing leaks is one of the fastest and most cost-effective energy efficiency improvements a business can make.

Repairing compressed air leaks can provide numerous benefits, including:

• Lower electricity costs
• Reduced operating expenses
• Improved compressed air system reliability
• Increased equipment performance
• Reduced wear and tear on compressors
• Extended equipment life
• Lower greenhouse gas emissions

What if there are a lot of leaks to fix?

If you find one or two leaks, it is easy to know where to start, but what if you have several (10 or more)? 

When the IWRC completes an assessment for a business, leaks are documented and quantified, allowing businesses to understand exactly how much compressed air—and money—is being lost. Participants receive a detailed report identifying the location of each leak, the estimated air loss, and the potential annual energy cost savings that can be achieved through repair.

Where can small businesses get help with compressed air assessments?

To help Iowa small businesses reduce energy costs and improve operational efficiency,  the IWRC offers free compressed air leak assessments.

Most compressed air leak assessments can be completed in one to two hours with minimal disruption to normal operations. There is no cost to participate, making this an excellent opportunity for Iowa small businesses to identify energy savings without investing in outside consulting services.

Whether your facility has a few air tools or an extensive compressed air system, this assessment can help uncover opportunities to reduce waste and improve efficiency.

If your business wants practical ways to lower operating costs and improve energy performance, now is the perfect time to schedule a free compressed air leak assessment.

For more information or to schedule an assessment, contact the Iowa Waste Reduction Center at the University of Northern Iowa.