5 Common Compressed Air Mistakes Costing You Thousands

Compressed air is essential in many industries but it’s also one of the most expensive utilities to generate. What’s worse is that much of this cost comes not from producing the air, but from avoidable inefficiencies in how it’s used and managed.

At Compressed Air Energy Solutions, we see the same issues come up time and time again - often costing businesses tens of thousands of pounds a year without them even realising it.

Here are five of the most common and costly mistakes.

1. Ignoring Air Leaks

This is the big one. Leaks are present in virtually every system we audit, and they can waste up to 20–30% of total air production.

Even a single 3mm hole can cost over £700 per year, and most sites have dozens. Worse still, many sites are producing extra compressed air just to compensate for losses they don’t know exist.

Fix: A professional leak survey followed by prompt repairs can lead to instant savings.

2. Running at Higher-Than-Necessary Pressure

Many sites run their system at higher pressure “just in case”. But every extra bar of pressure increases energy consumption by around 7% - without solving the root issue (which is usually pressure drop or demand spikes).

Running too high can also increase leak rates and shorten equipment life.

Fix: Audit your system to understand true demand, reduce pressure where possible, and address the real causes of pressure issues.

3. Poor Compressor Control Strategy

Too often, we see systems with multiple compressors running inefficiently - either fighting each other or running off-load unnecessarily.

Without proper control (or a central controller), fixed-speed compressors may be loading and unloading constantly, wasting energy with every cycle.

Fix: Implement a staged or centralised control strategy that prioritises the most efficient compressor for the load.

4. No Monitoring or Data Logging

“You can’t manage what you don’t measure.”

Without data, decisions around pressure, equipment sizing, and compressor control are guesswork.

Many businesses upgrade or add compressors without ever measuring demand - leading to oversized systems and wasted energy.

Fix: Use temporary or permanent logging (flow, pressure, amps) to gain visibility, and base decisions on real-world data.

5. Ignoring Pressure Drop in the System

Pressure drop happens when compressed air travels through undersized pipework, poor layouts, long runs, or restrictive components like filters and fittings.

This drop can lead to operators increasing system pressure - creating a vicious (and costly) cycle.

Fix: Review pipework layout, sizing, and condition. Check filters for differential pressure. Don’t just turn the pressure up - solve the restriction.

Final Thoughts

Most compressed air inefficiencies are invisible - until someone measures them. That’s where we come in.

At Compressed Air Energy Solutions, we help businesses across the UK identify waste, log system performance, and make smarter decisions using real data - not assumptions.

If you're concerned about rising energy costs or want to get a handle on your compressed air system, let’s talk.