Compressed Air Systems
Compressed air accounts for 10 to 30% of total electricity consumption on most manufacturing sites. Industry estimates suggest between 20 and 30% of compressed air generated is lost to leaks before it reaches a tool or process.
Pro Enviro surveys your compressed air system, identifies leaks and inefficiencies, and manages the most cost-effective improvement programme - from leak repair and pressure optimisation through to full compressor replacement and installation of variable speed drive units and heat recovery systems.
Annual cost of leaks running at 7 bar, 8,760 hours per year. A typical manufacturing site has dozens of leaks — combined annual cost frequently exceeds £50,000.
THE COST OF LEAKS
A single 3mm leak in a compressed air line running at 7 bar costs approximately £700 per year in wasted electricity. A systematic leak detection and repair programme typically delivers 15 to 25% energy savings on the compressed air system - often the fastest payback measure on the site.
Where compressed air energy goes
Our process
Ultrasonic leak survey
Full site survey using ultrasonic detection. Every leak logged with location, size, and annual cost.
Pressure mapping
Measurement at multiple points to identify drops and over-pressurisation.
Compressor review
Assessment of type, age, loading pattern, and sequencing against actual demand.
Heat recovery assessment
Quantification of recoverable heat and viable recovery applications.
Improvement programme
Prioritised action plan with costs, savings, and payback for each measure.
Post-repair verification
Return visit to confirm savings against pre-survey baseline data.
Typical savings
Leak detection and repair: 15 to 25% reduction in compressed air energy
Pressure reduction of 1 bar: approximately 7% compressor energy saving.
VSD compressor replacing fixed-speed unit at 50% load: 30 to 35% energy saving.
Heat recovery from compressor: up to 80% of compressor energy recovered as usable heat.
Combined programme: 30 to 50% reduction in total compressed air energy cost achievable on most sites.
What we assess
We use ultrasonic detection equipment to identify leaks throughout the distribution system - at fittings, hoses, couplings, and valves. Every leak is logged with location, estimated size, and annual energy cost, giving you a prioritised repair programme with costs and payback for each.
Most systems run at higher pressure than the highest-demand application actually requires. Reducing system pressure by 1 bar reduces compressor energy consumption by approximately 7%. We review demand across all applications and identify the minimum viable system pressure.
Fixed-speed compressors running at part load are highly inefficient. Where replacement is warranted, Pro Enviro specifies and manages the installation of new compressors - including variable speed drive (VSD) units that modulate output to match demand. We also assess sequencing and control strategies where multiple compressors are installed, and can manage the full procurement and installation process through qualified partners.
Approximately 80% of the electrical energy consumed by a compressor is converted to heat. In most installations this is rejected to atmosphere. A heat recovery system can redirect it to space heating or process heating - free heat from a system that already exists.
Interested in reducing your compressed air costs?
Speak to our team to arrange an initial compressed air survey for your site.