Average leak cost
About $600 per leak, with a common range of $250–$1,900.
Compressed-air optimization
Find the leaks and wasted horsepower hiding in compressed air
Compressed air is often the most overlooked and expensive utility in a manufacturing plant. The U.S. Department of Energy estimates that 10–30% of industrial energy use can go to compressed air, and that leaks can consume about 30% of compressor energy.
What this work covers
Compressed-air optimization
Over the past four years EDE has partnered with manufacturers including Martinrea, Antolin, Kautex, Tenneco, Worthington, Brembo, Magna, and Flex-N-Gate, delivering nearly $2 million in collective compressed-air energy savings. Our compressed-air team brings more than 80 years of collective plant experience.
Leaks matter. So do compressor controls, pressure settings, sequencing, and demand when production stops. We begin with compressor data logging, typically over one week, to observe operation across production and off-shift periods. We then perform ultrasonic leak detection to locate and document air losses. Where the agreed scope calls for a longer look, monitoring can run for up to two weeks to find sequencing, pressure, storage, and demand issues without disrupting production.
This sequence gives the leak findings context. It helps us evaluate what the compressors are doing, when demand occurs, and which operating changes deserve further investigation. The assessment will determine the opportunity; we do not assume a fixed savings percentage for every plant.
In this work
What a typical leak audit uncovers
Volume
60–250 leaks per audit, depending on facility size.
Example
80 leaks at $600 each is $48,000 in annual leak cost before labor.
Utility support
Most utilities pay for professional leak audits, which finds more leaks than walk-around listening or soapy water.
Compressor-room mistakes we still see
- Wrong compressor type or sizing
- Controls software installed but unused
- Leak programs that still miss 60–70% of leaks
- Poor air treatment, heat, and ventilation
- One auditory leak walk per year treated as a complete program
We explain what we measured, what the findings suggest, and where additional investigation is needed. Your team can use the results to prioritize repairs and operating changes, with implementation and verification defined for the selected work.
If your plant is considering another compressor, understanding current demand and system operation can help inform that decision. Already repaired leaks, or recently purchased a compressor? You may still have operating questions worth investigating.
Call EDE at (734) 215-1133 or request a facility energy review. This is the only plant-support number we publish.
Primary offer
Request a 30-minute facility energy review
Name, company, and a way to reach you. Tell us which system is keeping you up at night.
Prefer a call? (734) 215-1133
