Maximising Efficiency: Air Compressor Audits UK
A compressed-air audit helps identify where electricity is being used, where pressure or airflow is being lost, and which improvements are most likely to reduce operating cost without compromising production.
Data Logging
Leak Detection
Pressure Review
Demand Profiling
VSD Opportunities
Pipework & Air Treatment
Why Audit a Compressed Air System?
Compressed air can consume a significant amount of electricity, but energy loss is not always caused by the compressor itself. Leaks, unnecessary pressure, unloaded running, restrictive filtration, poor pipework and badly matched equipment can all increase cost.
An audit brings those factors together so decisions can be based on measured demand rather than assumptions.
Important: an audit should identify opportunities and quantify them where suitable data is available. It should not promise a fixed percentage saving before the system has been measured.
What Should a Proper Audit Look At?
Compressor LoadingHow much time each machine spends loaded, unloaded, stopped or running at part load.
PressureCompressor setpoints, pressure drop and the actual pressure required at point of use.
Air DemandDaily demand, peaks, troughs and out-of-hours consumption.
LeakageLeaks in fittings, valves, hoses, drains, pipework and production equipment.
Air TreatmentDryers and filters that may be creating unnecessary pressure loss.
DistributionPipe diameter, layout, receiver storage and pressure stability across the site.
Audit Levels: From Initial Review to Detailed Data Logging
Initial System Assessment
A practical first review can identify obvious issues such as leaks, excessive pressure, poor ventilation, ageing equipment or unsuitable distribution.
Data-Logging Audit
Where better evidence is needed, logging can record pressure, power and operating behaviour over a representative production period.
Duration varies by site. Logging should cover a period that captures the site’s normal operating pattern; it is not automatically a fixed 7–14 day exercise.
ISO 11011 and Compressed Air Assessments
ISO 11011 provides a framework for assessing compressed-air systems, covering supply, transmission and demand. It is useful when a structured assessment methodology is required.
However, simply carrying out an audit does not automatically make a site “ISO compliant” or certify it to ISO 50001. Those standards have their own requirements and certification processes.
Common Opportunities an Audit May Uncover
- Repairing compressed-air leaks
- Reducing compressor pressure
- Stopping unnecessary out-of-hours running
- Replacing blocked or restrictive filters
- Changing compressor sequencing
- Introducing VSD where demand varies
- Improving receiver storage
- Correcting undersized or restrictive pipework
Existing Products From the Original Article — All Kept
The original live post contains eight product cards. Every one of those product routes and its existing image has been retained below.
Existing Article Product
Siltek TB 100T/4 Super Quiet
11.6 CFM • 8 Bar • 230V • Oil-Free • 64 dB(A)
Existing Article Product
Power Systems G-TEC 1108-270 DF DV
23–58 CFM • 8 Bar • 270L • VSD • Dryer + Dual Filtration
Existing Article Product
Power Systems NOBEL 5.510-270
25 CFM • 10 Bar • 270L • Fixed Speed
Existing Article Product
Power Systems NOBEL 7.508 DV
21–46 CFM • 8 Bar • Floor Mounted • VSD
Existing Article Product
Power Systems NOBEL 7.510 DF
37 CFM • 10 Bar • Floor Mounted • Dryer + Filters
Existing Article Product
Power Systems NOBEL 7.508-270 DV
21–46 CFM • 8 Bar • 270L • VSD
Existing Article Product
Power Systems G-TEC 7.508-270 DF
44 CFM • 8 Bar • 270L • Dryer + Dual Filtration
Existing Article Product
Power Systems FLEMING 2.208
8.8 CFM • 8 Bar • Oil-Free • Silenced Cabinet
Our Tanair VSD Range — Also Worth Comparing After an Audit
If measured demand shows that a variable-speed compressor is appropriate, the Tanair TAN-S permanent-magnet VSD range gives a direct route from 19 CFM through to 113 CFM at 10 bar.
Tanair PM VSD Range
Tanair TAN-S 5.5VSD
5.5 kW • 19 CFM • 10 Bar • 415V
Tanair PM VSD Range
Tanair TAN-S 7.5VSD
7.5 kW • 32 CFM • 10 Bar • 415V
Tanair PM VSD Range
Tanair TAN-S 11VSD
11 kW • 46 CFM • 10 Bar • 415V
Tanair PM VSD Range
Tanair TAN-S 22VSD
22 kW • 113 CFM • 10 Bar • 415V
Do not replace from the audit headline alone. Use the logged airflow, pressure and demand profile to decide whether VSD, fixed speed, sequencing changes or system repairs offer the best return.
How to Turn Audit Data Into a Business Case
| Finding | Possible Action | Decision Data |
|---|---|---|
| High leakage | Leak repair programme | Estimated lost CFM and annual run hours |
| Excess pressure | Lower setpoint / reduce pressure drop | Point-of-use pressure requirement |
| Long unloaded periods | Review sizing, controls or VSD | Load/unload profile and kW consumption |
| Unstable pressure | Review receiver storage and distribution | Pressure trend and demand peaks |
| Old inefficient compressor | Compare replacement options | Existing power draw vs required airflow |
Choosing an Audit Provider
- They should understand compressor operation as well as distribution and point-of-use demand
- Recommendations should be based on measured or clearly stated assumptions
- They should explain how estimated savings were calculated
- They should distinguish repair opportunities from equipment-replacement opportunities
- The final recommendations should be practical for the site’s production priorities and budget
Air Compressor Audit FAQs
What is the difference between an assessment and a full audit?
An assessment may be a shorter visual and operational review. A fuller audit generally adds measured data such as pressure, power and demand over a representative period.
How long does an audit take?
It depends on the site and the production pattern. Data logging should run long enough to capture representative demand, including relevant shifts and shutdown periods.
Can an audit identify air leaks?
Yes. Leak detection can be included as part of a wider efficiency review or carried out as a dedicated survey.
Does an audit mean I need a new compressor?
No. Repairs, pressure changes, leak reduction, maintenance or control improvements may sometimes be more cost-effective than replacement.
Can an audit help determine whether VSD is suitable?
Yes. A measured demand profile is one of the best ways to assess whether variable-speed control is likely to provide a genuine benefit.
Compressed Air Systems UK
The original article’s Contact Us and Birmingham routes remain in place. For energy-saving audits, leak detection, system reviews or compressor selection, contact the team.
Offices, Trade Counter & Warehouse
Compressed Air Systems UK
Unit 15, Fortnum Close
Birmingham, B33 0LG
Call 0121 753 3330 or use the Contact Us page.
Want to Know Where Your Compressed Air Is Costing Too Much?
Start with the system data, then prioritise the improvements that offer the strongest operational and financial case.