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Air Pressure

Leaks in compressed air systems are a common occurrence and can be a significant source of energy loss for a facility, often wasting 20-30% of a compressors output.

Industrial Efficiency Partners team has been working with manufacturers for decades helping to identify opportunities for increased efficiency.  As we see cost rising in every area efficiency has never been more critical.

About Us
Air Compressors


At Industrial Efficiency Partners, we specialize in industrial air leak detection. We use advanced ultrasonic imaging technology to help customers see where air leaks occur through our detailed on-site air leak survey, allowing them to prioritize which ones to fix first. We provide full reporting to show the annual cost of each leak and a cumulative loss report to show the overall impact of leaks on their energy consumption. Our goal is to help customers reduce their energy costs and become more efficient.

Gas Plant
Cost of Leaks

Cost of air leaks - US Department of Energy

Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20%-30% of the compressor’s output. Compressed air leaks can also contribute to problems with system operations, including: • Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efficiently, possibly affecting production • Excess compressor capacity, resulting in higher than necessary costs • Decreased service life and increased maintenance of supply equipment (including the compressor package) due to unnecessary cycling and increased run time. Although leaks can occur in any part of the system, the most common problem areas are couplings, hoses, tubes, fittings, pipe joints, quick disconnects, FRLs (filter, regulator, and lubricator), condensate traps, valves, flanges, packings, thread sealants, and point-of-use devices. Leakage rates are a function of the supply pressure in an uncontrolled system and increase with higher system pressures

Average Yearly Cost of Air Leaks Based on Leak Size

  • 1/64″ diameter = .45 CFM = $47/year

  • 1/32” diameter = 1.6 CFM = $198/year

  • 1/16” diameter = 6.45 CFM = $800/year

  • 1/8″ diameter = 25.8 CFM = $3,208/year

  • 1/4″ diameter = 103 CFM = $12,812/year

  • 3/8″ diameter = 234 CFM = $29,113/year

Car-making factory

IEP Process

Air Leak Assessment Process


Initial virtual meeting to discuss the scope of the project, goals, expectations, and basic compressed air system details.


On site compressed air system audit using specialized ultrasonic equipment to identify leaks while your facility remains in operation.  Leaks are identified, tagged, and documented. 


On completion, you will receive a full project plan, leak report, action plan and impact summary documenting the financial and operating improvements expected from fixing the leaks. Your operational efficiency and total cost of ownership will be positively impacted as a result of IEP's clear, structured process that identifies and prioritizes improvement actions.

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