Getting the Most out of Your Compressed Air System

Compressed air: you can’t see it, but you’d definitely notice if it went away. Whether you're in automotive manufacturing, food and beverage production, packaging, or mining, compressed air is probably a key part of your daily operations. In fact, roughly 70% of manufacturers rely on compressed air for everything from running machine tools to collecting dust.

Despite how common it is, compressed air is also one of the least energy-efficient utilities in a facility. That's why it’s so important to optimize it—not only to keep your systems running smoothly but also to save on energy costs and reduce downtime.

A few key areas to help you do just that:

• How to increase energy efficiency in your compressed air system
• Ways to reduce downtime and keep things running reliably
• Emerging technologies and trends in compressed air
• Important safety tips to keep your team protected

Let’s dive in.

Boosting Energy Efficiency in Your Compressed Air System

Compressed air is a powerful tool, but it can be a serious energy hog if not managed properly. The good news? Small changes can make a big difference. Here’s how to make your system more efficient and cost-effective:

1. Fix Those Leaks

Leaks are the silent killers of energy efficiency. On average, about 20–30% of compressed air gets lost to leaks—and that’s like throwing money out the window.

The best way to hunt down leaks is with an ultrasonic acoustic detector, which picks up the high-frequency sound of air escaping. This is also called an air leak detection audit, that can be done by a pneumatic specialist.  No fancy tools? No problem. A simple soapy water spray can reveal leaks too—just look for bubbling.

Most leaks happen in familiar spots: valves, fittings, hoses, and joints. Once you find them, repairs can be as easy as tightening a connection or swapping out worn components. Even custom parts can be replaced quickly with a U.S. based custom valve assembly service.  And when you fix them, you’ll often see energy losses drop to under 10%.

2. Rethink Energy-Hungry Applications

Some applications just eat up compressed air. The key is figuring out which ones and finding alternatives that get the job done for less energy.

For example:

• Using a pneumatic vibrator on a hopper? Consider switching to an impact cylinder that delivers a quick, controlled shock.
• Relying on vortex tubes to cool electrical cabinets? Try adding a thermostat and shutoff valve to only cool when it’s needed.
• Running vacuum venturis 24/7? Upgrade to a multi-stage version with auto shutoff so it only runs when absolutely necessary.

These kinds of tweaks can add up to big savings over time.

3. Lower the Pressure (When You Can)

When machines are idle, you don’t need full system pressure. Lowering the pressure during downtime is a simple way to cut energy use without slowing you down when you’re ready to restart.

Use automated controls and pressure regulators to dial things back during standby. As a rule of thumb, every 2 psi you reduce can save about 1% in energy. Multiply that over hundreds of hours, and you’ve got a noticeable difference in your utility bill.

4. Don’t Overpressurize

More pressure isn’t always better. In fact, overpressurizing a system can lead to premature wear, wasted energy, and even safety risks.

The right pressure should match the specific needs of your tools and actuators. Most of the time, this is lower than what’s coming from the compressor room. If you see similar machines running at different pressures, that’s a sign to investigate—something may be misconfigured.

Use manual or electro-pneumatic regulators to fine-tune your system and monitor pressure regularly to avoid unnecessary spikes.

Evaluating your systems to optimize energy usage can be a tedious task. Taking advantage of a pneumatic subject matter expert can reduce stress and labor hours used on combing over every application in your facility. Start the conversation today and start saving on utilities. Contact Us.