Detection and prevention of leaks in compressed air systems

Even the smallest leaks in pneumatic systems lose large amounts of air quickly and continuously, which noticeably increases operating costs. For example, a single hole just 1 mm in diameter (!!!) can waste 5,125 kWh of electricity a year. One 1 mm hole… and how many such openings, larger and smaller, can there be in a system?

We are sure you have heard hissing on a pipe or quick coupling at least once. If a leak is loud enough to hear, it is a significant source of cost. Multiply the electricity consumption caused by leaks by the industrial price per kWh and you get a clear calculation of the direct loss – of air and of money.

01How much a leak costs at 8 bar

Leak size	Air leaking at 8 bar	Air lost per year*	Energy lost per year**
1 mm	75 l/min	39,420,000 l	5,125 kWh
2 mm	260 l/min	136,656,000 l	17,765 kWh
3 mm	600 l/min	315,360,000 l	40,997 kWh
4 mm	1,100 l/min	578,160,000 l	75,161 kWh

* With the compressor station running 24 hours a day all year round. ** Based on the additional motor power needed (0.13 kW per m³ of compressed air) to supply the air lost.

02The negative effects of compressed air leaks

Pressure drop in the network, which reduces the efficiency of machines and tools
More on/off compressor cycles, shortening the life of the compressor and other system components
Higher overall equipment maintenance costs and shorter service intervals
The need for an additional compressor because the existing one lacks effective capacity due to leaks – not because the air is being used efficiently

03A smarter solution

Rather than buying a compressor to cover leak losses, there is a smarter solution: inspect your compressed air system, take the necessary measures and turn your system into a profitable part of your operation! Sometimes even very small corrections are enough to change the efficiency of the entire system.