How to Improve Compressed Air System Efficiency

Don’t know where to start with compressed air efficiency?

A focused energy audit highlights the biggest savings...

Why Start with a Compressed Air Audit?

Compressed air systems are rarely identical - what works efficiently in one setup might waste energy in another. That’s why a compressed air audit is the best place to start. It gives us a full picture of how your system is performing, based on real data - not guesswork.

By logging key parameters like flow, pressure, temperature, and power consumption over a typical working week, we can identify the biggest opportunities for improvement. Every system has its own hidden inefficiencies, and the audit allows us to dig deeper into areas that matter - whether that’s high offload running hours, out-of-hours demand, leaks, pressure drops, or poor control strategy.

At Compressed Air Energy Solutions, we carry out independent, brand-neutral audits tailored to your site. No generic software reports. No sales pitches. Just actionable insight to help you reduce energy waste, improve reliability, and cut costs.

Our Data Logging Process – How It Works

Once we’ve agreed to carry out an audit, the next step is to install our data logging equipment on your compressed air system during a typical working week - with no disruption to your production.

Here’s what the process looks like:

Installation: We fit our loggers onto your compressors and key parts of the system. This might include pressure transducers, flow meters, dew point sensors, and current clamps - depending on what’s already in place and what we need to measure.

Monitoring: Over the course of 7 days, we gather live data on flow, pressure, temperature, dew point, and power usage. This helps us understand how your system performs under normal operating conditions.

Data Collection: After the monitoring period, we retrieve the loggers and extract the data for detailed analysis.

Analysis: This is where we go beyond generic software reports. Every system is different, so we manually review the data to ensure the results are accurate and relevant to your setup.

This process gives us the hard evidence we need to pinpoint where energy is being wasted and lays the groundwork for everything else that follows, from identifying quick wins to building long-term efficiency strategies.

What Will the Audit Report Include?

Once we've analysed the data, you'll receive a clear, tailored report that shows how your compressed air system is performing — and where the biggest opportunities for savings lie.

Annual Running Costs - We calculate the true cost of running your compressors, based on actual kWh usage and operating hours.

Energy Saving Opportunities - We highlight where energy is being wasted and outline practical improvements that can be made. The report also flags any areas that may require further investigation — such as inconsistent pressure profiles, abnormal demand patterns, or underperforming equipment.

Return on Investment (ROI) - Each recommendation includes a breakdown of estimated implementation cost, potential savings, and indicative payback period.

Typical ROI for compressed air improvements can range from a few months to under 2 years, depending on site conditions.

CO₂ Emission Reductions - We estimate the carbon savings based on your energy reduction potential.

What Can Our Audit's Reveal?

• Excessive offload power consumption

• Out-of-hours demand

• High baseline usage (leaks)

• Control system inefficiencies

• Dew point & temperature problems

• Pressure drops across filters/dryers

• Heat Recovery Potential

• Poor Specific Efficiency

Ready to Take Control of Your Compressed Air Efficiency?

Don’t let inefficiencies drain your resources. Contact Compressed Air Energy Solutions today to schedule your tailored audit.