Rising electricity costs mean compressed air inefficiencies are costing UK manufacturers thousands of pounds every year. Poorly maintained systems, air leaks, incorrect sizing and inefficient operation all contribute to unnecessary energy spend and increased carbon emissions.

At Compressed Air Systems UK, we deliver ISO 11011–compliant compressed air energy saving audits that provide a clear, data-driven understanding of how your system is performing. Our audits identify inefficiencies, quantify energy losses and present verified savings, carbon reduction and return on investment (ROI)—allowing informed decisions without guesswork.

What Affects Compressed Air Energy Efficiency?

Compressed air systems rarely operate at peak efficiency. Common causes of excessive energy consumption include:

• Air leaks

• Poorly maintained equipment

• Incorrectly specified compressors

• Poorly sized or poorly designed pipework

• Long distances between compressor and point of use

• Excessive bends, restrictions and pressure losses

Addressing these issues can deliver significant and measurable reductions in energy use.

ISO 11011 Compressed Air Energy Audits

All of our compressed air usage audits are carried out in accordance with ISO 11011, the international standard for compressed air system energy assessments.

We use independent data logging equipment, ensuring results are not manufacturer-driven. Our sole focus is to reduce your energy consumption, operating costs and carbon footprint—supporting wider sustainability and Net Zero objectives.

How Our Compressed Air Energy Saving Audit Works

Our audit process is designed to capture real operating conditions and provide actionable insight:

1. System review and site assessment
   Evaluation of compressor sizes, system layout, pipework design, operating pressures and air usage points.

2. ISO 11011 data logging (minimum 14 days)
   Independent data loggers are installed to monitor performance across varying production demands, including weekends.

3. Leak detection and misuse identification
   Identification of air losses, inappropriate compressed air use and system instability.

4. Energy, cost and carbon analysis
   Assessment of electricity consumption, true power usage, operating efficiency and carbon reduction opportunities.

5. ROI evaluation and reporting
   A detailed report outlining achievable energy savings, payback periods and optimisation recommendations.

What We Measure During the Audit

Our data logging equipment allows us to build a detailed picture of your system’s performance, monitoring:

• Pressure

• Flow rate

• Temperature

• Moisture dew point

• Compressor load / unload cycles

• Energy consumption (kW and kWh)

• Current, voltage and power factor

• Carbon reduction potential

All logged data is analysed and presented in a comprehensive report, highlighting clear opportunities for energy and cost savings.

What We Assess During an Energy Audit

During the audit, our engineers focus on key operational and cost factors, including:

• Compressor kW sizes and configuration

• Number of compressors installed

• Production processes and compressed air demand

• Shift patterns and operating hours

• Electricity costs on site

• Required pressure, flow and dew point

• Duration and scope of leak detection surveys

• Identification of obvious leaks and misuse of compressed air

Recommendations are always site-specific and based on measured data.

Why Data Logging Is Essential

To optimise a compressed air system, accurate data is essential. Data logging allows inefficiencies to be identified and quantified under real operating conditions.

Data loggers should be installed for a minimum of 14 days to capture variations in demand. While compressor energy ratings are provided by manufacturers, data logging reveals how the entire system performs in practice.

Logged data is analysed to determine whether cost savings, efficiency improvements and carbon reductions can be achieved.

Additional Uses of Data Logging

Beyond energy audits, data logging supports long-term compressed air management:

1. Establishing a Performance Baseline

A baseline allows future comparisons and highlights deviations from expected performance. Key units of measurement include:

• kW – instantaneous power consumption

• kWh – total energy usage (used for electricity billing)

If performance deviates from the baseline or manufacturer specifications, this often indicates system issues.

2. Troubleshooting System Issues

Data logging allows engineers to review system conditions at the exact time a fault or inefficiency occurred.

3. Ensuring Pressure Stability

Monitoring pressure, flow and compressor power enables identification of instability and poor system control.

4. Correct Equipment Sizing

Data logging helps avoid costly mistakes when replacing or upgrading compressors by providing accurate demand profiles.

5. Verifying Energy Savings

Measured data confirms that predicted savings are achieved following system improvements or capital investment.

This audit is ideally suited to:

– Sites with multiple compressors
– Businesses experiencing rising energy costs
– Systems with unknown leakage rates or instability
– Organisations working towards Net Zero targets

It may not be suitable for very small, single-compressor installations or sites unwilling to collect real operating data.

Proven Energy Savings

For example, a two-week data logging audit carried out for a UK manufacturer identified opportunities delivering £23,637 in annual energy savings.

The question is: where would you invest an extra £23,637 in your business?

This audit is ideally suited to:

– Sites with multiple compressors
– Businesses experiencing rising energy costs
– Systems with unknown leakage rates or instability
– Organisations working towards Net Zero targets

It may not be suitable for very small, single-compressor installations or sites unwilling to collect real operating data.

Compressed Air Energy Saving Audit FAQs

What is an ISO 11011 compressed air audit?
ISO 11011 is the international standard for compressed air energy audits, ensuring assessments are data-driven, independent and focused on measurable savings.

Do we need to shut down production?
No. Data loggers are installed while systems remain operational.

How accurate are the savings estimates?
Savings are calculated using logged system data, operating patterns and electricity costs—not assumptions.

What happens after the audit?
You receive a detailed report outlining energy savings, carbon reduction and ROI. Any next steps are optional.

Estimate Your Potential Savings Before an Audit
Want an early indication of how much energy and money your compressed air system could be costing you?

👉 Use our Compressed Air ROI Calculator to estimate annual energy costs, savings and payback based on your system kW, operating hours and electricity rate.

Want to learn more?

• Energy Saving Audit – diagnostic and authority hub

• ROI Calculator – commercial evaluation and early engagement

• Leak Detection Services – corrective action identified during audits

• Case Studies – proof of real-world savings and outcomes.