Compressed Air Audit Services

A compressed air audit conducted by Comairco’s team of certified auditors is the most effective way to maximize your system’s efficiency. Designed to identify energy-saving opportunities, a compressed air energy audit often uncovers simple yet impactful solutions—such as minor piping adjustments, cost-effective compressor control tweaks, or adding storage capacity paired with precision flow controllers. Every compressed air system is unique, and our audits are tailored to address your specific needs for optimal performance.

Often, compressed air audits reveal enough savings to allow compressors to be turned off entirely. These audits can be integrated into existing maintenance contracts, enabling regular re-assessments as your facility, systems, environment, and compressed air requirements evolve over time.

What Is a Compressed Air Audit?

A compressed air audit typically begins with a walk-through evaluation, which serves as the first step in understanding how your system is operating. This initial review can be conducted by facility personnel or, more effectively, by Comairco’s experienced compressed air specialists. During this stage, major inefficiencies such as leaks, improper controls, pressure losses, and unnecessary demand are identified.

While a walk-through does not provide the detailed analysis of a full system assessment or engineering study, it often delivers immediate value. Many facilities achieve energy savings of 25% or more, along with reduced maintenance costs, simply by addressing the issues uncovered during this initial evaluation.

Following the walk-through, Comairco works with your team to determine whether additional analysis is beneficial. For larger or more complex systems—or when critical issues are identified—a more in-depth evaluation may be recommended. These advanced assessments provide detailed insight into system dynamics, including supply and demand relationships, and help uncover root causes of inefficiencies to develop targeted, high-impact improvement strategies.

Comairco tailors each audit level to match your facility’s size, complexity, and operational goals—ensuring you receive the right level of analysis to maximize efficiency, reliability, and long-term cost savings.

Levels of Compressed Air Audits

Level 1: Walkthrough Evaluation

A Level 1 Walkthrough Evaluation provides a high-level overview of a facility’s compressed air system, focusing on identifying the types of end uses, system demands, and the appropriateness of pressures and air quality requirements. During this evaluation, Comairco analyzes the distribution system for visible issues such as improper sizing, pressure drops, inadequate storage, leaks, and ineffective condensate management. The supply side is also reviewed, including compressor types, control strategies, and overall operating settings to determine suitability and efficiency. A simplified block diagram of the system is developed to illustrate airflow and system layout, while maintenance practices and operator training are assessed for potential improvements. At the conclusion of the evaluation, a detailed written report is provided, outlining key findings along with recommended actions to improve system performance, reliability, and energy efficiency.

Level 2: System Assessment

A Level 2 System Assessment provides a more detailed analysis of a facility’s compressed air system, building upon the findings of a walkthrough evaluation. In addition to identifying system components, demands, and visible issues, Comairco collects data readings at key points throughout the system to better understand operating dynamics such as pressure fluctuations, airflow demand, and system performance. The assessment includes developing a simplified system block diagram along with pressure and demand profiles to pinpoint inefficiencies and identify opportunities for improvement. Maintenance practices and operator training are also reviewed to ensure proper system operation. Following the assessment, a comprehensive written report is provided with findings and recommendations, presented in a solution- and product-neutral manner, allowing facilities to make informed decisions that improve efficiency, reliability, and overall system performance.

Level 3: Comprehensive System Audit

A Level 3 System Audit provides the most comprehensive and in-depth evaluation of a facility’s compressed air system, expanding on the analysis performed during a system assessment. This level includes detailed data logging over an extended period, capturing key system parameters such as pressure, flow, and power consumption to fully understand system dynamics and identify root causes of inefficiencies. Maintenance procedures and operator training are again reviewed to ensure proper system operation and long-term reliability. The primary objective of a system audit is to achieve proper alignment between the supply side and demand side, maximizing energy efficiency, system performance, and reliability. A performance baseline is established during the audit, allowing for accurate measurement of improvements resulting from recommended changes. Upon completion, Comairco delivers a comprehensive written report outlining all findings, detailed recommendations, and projected results, providing a clear roadmap for optimizing your compressed air system.

How a Compressed Air Audit Works

A key part of an effective compressed air audit is establishing an accurate system baseline using the proper measurement tools. Data loggers and flow meters play a critical role in this process by capturing real-time system performance over an extended period. Data loggers are connected to pressure sensors, flow meters, and power meters to continuously record parameters such as system pressure, airflow (CFM), and energy consumption. This data is used to develop detailed pressure, demand, and energy profiles, allowing Comairco to identify fluctuations, inefficiencies, and opportunities for system optimization. Flow meters, whether installed inline or as insertion-style devices, measure the actual air consumption throughout the system. When properly selected based on air quality, installation requirements, and accuracy, these instruments provide reliable insight into demand patterns and system behavior. Together, data loggers and flow meters enable a deeper understanding of how the compressed air system operates, forming the foundation for developing effective control strategies, improving efficiency, and validating performance improvements over time.