Compressed Air Leaks: The Real Cost & How to Fix Them

How to build a leak management program

Every plant should develop a structured program to assess and correct leaks in its system on an ongoing basis. Small leaks turn into big leaks in a short period of time when left alone.

1. Choose your detection method

You have two options: purchase your own ultrasonic leak detector, or contract the audits to a company that performs this service. The right choice depends on the size of your plant and your in-house resources.

2. Divide the plant into quadrants

Many large plants try to audit the entire facility at once, only to find that fixing every leak simultaneously is overwhelming.  We have seen leak tags still hanging a year — sometimes two years — later, never repaired.  The recommended approach: divide the plant into four sections and audit one section per quarter. You cover the full facility once a year with a realistic workload. As the old saying goes, the best way to eat a 500-pound elephant is one bite at a time.

3. Tag and repair quickly

The goal is to identify, tag and fix each leak as soon as possible. A leak management program isn’t a one-and-done project — it’s an ongoing strategy that keeps your leak load permanently under control.

What leak rate should you target?

A respectable target is no more than 10% of your total air consumption lost to leaks.  In plants with no active program, that figure often exceeds 20–30%. Every percentage point above 10% means your compressor is running — and consuming — for nothing.

 

FAQ

 

How much does a compressed air leak cost per year?

A ¼” leak at 120 psi costs approximately $10,000 per year at $0.05/kWh, and up to $20,000 at $0.10/kWh — a more representative blended rate for many Canadian and U.S. facilities. Since most plants have several leaks running simultaneously, total annual losses can easily exceed $50,000 without a formal leak management program.

What percentage of compressed air is typically lost to leaks?

Industry best practice sets the acceptable threshold at under 10% of total air consumption. In plants with no active program, that figure often exceeds 20–30%. At that level, the compressor is running unnecessarily for a significant portion of its operating hours — and you’re paying for every one of them.

How do you detect compressed air leaks?

The most effective non-intrusive method is an ultrasonic leak audit. A certified technician uses an ultrasonic detector to locate leaks without stopping production, then tags them for repair and prioritizes them by size and location.  A data-logged air audit is a strong complement. It measures consumption over seven days and quantifies total leak load during non-production hours.

How often should I perform a compressed air leak audit?

For mid-to-large facilities, divide the plant into four quadrants and audit one quadrant every three months. This keeps the repair workload manageable and delivers full plant coverage once a year — without trying to fix everything at once.

Should I buy my own ultrasonic leak detector or hire a specialist?

Both options are valid. Purchasing a quality detector makes sense for large facilities with frequent audits and dedicated maintenance staff. For smaller plants or those without in-house expertise, contracting a specialist like Comairco is typically more cost-effective. It also provides certified interpretation and a formal audit report — documentation that can support energy rebate applications with your local utility.

 

Measure your plant’s leak load

Comairco performs data-logged air audits and ultrasonic leak audits across Canada. Planning to buy your own detector instead? Call us anyway — we’re happy to share free, friendly advice that will make your facility more energy efficient, with no obligation.