Compressed Air Leak Audits

Compressed Air Leak Audits for Northeast Manufacturers

From New York and Pennsylvania to New Jersey, New Hampshire, Massachusetts, Maine, and West Virginia, industrial facilities rely on compressed air for production, automation, packaging, assembly, and process applications. Even a well-maintained compressed air system can develop leaks that increase operating costs and reduce system efficiency. COMAIRCO helps facilities throughout the Northeast identify and prioritize leak repairs using advanced ultrasonic leak detection technology.

Industries We Serve

• Manufacturing
• Food & Beverage
• Pharmaceutical
• Plastics
• Automotive
• Aerospace
• Chemical Processing
• Metal Fabrication
• Electronics
• Wastewater Treatment
• Pulp & Paper
• Energy & Utilities

Why Perform a Compressed Air Leak Audit?

Compressed air systems naturally develop leaks over time at fittings, hoses, couplings, valves, regulators, filters, and production equipment. Without a structured leak management program, these losses can represent a significant percentage of total compressed air consumption.
An ultrasonic leak audit helps:

• Reduce energy consumption
• Lower operating costs
• Improve system reliability
• Reduce compressor run time
• Extend equipment life
• Improve system pressure stability
• Support sustainability initiatives

How Ultrasonic Leak Detection Works

Compressed air leaks generate high-frequency sound waves that are typically inaudible to the human ear. COMAIRCO technicians use specialized ultrasonic leak detection equipment to locate leaks while your facility remains in operation.
Each leak is:

1. Identified
2. Tagged
3. Documented
4. Quantified
5. Prioritized for repair

The final report provides actionable recommendations that help maintenance teams focus on the costliest leaks first.

What Is Included in a Leak Audit?

Our compressed air leak audits typically include:

• Facility walk-through
• Ultrasonic leak detection survey
• Leak tagging and identification
• Estimated leak flow calculations
• Annual energy cost estimates
• Prioritized repair list
• Summary report
• Follow-up recommendations

Common Sources of Compressed Air Leaks

Leaks are commonly found at:

• Quick-connect fittings
• Flexible hoses
• Pipe joints
• Valves
• Regulators
• Air dryers
• Filters
• Condensate drains
• Pneumatic tools
• Production equipment

Many facilities are surprised to learn that numerous small leaks can cost more than a single large leak.

How Much Can Compressed Air Leaks Cost?

In many Northeast manufacturing facilities, compressed air systems operate 24 hours per day. Even a small leak can waste thousands of dollars annually in electricity costs and increase compressor run time. Multiple undetected leaks can significantly impact plant energy consumption and production efficiency.

A structured leak management program can help facilities maintain leak losses below acceptable targets and continuously improve compressed air system efficiency.

Leak Audits and Compressed Air Audits

Compressed air leak audits are often performed alongside data-logged compressed air audits.
Combining both services allows facilities to:

• Measure demand
• Analyze system pressure
• Evaluate compressor performance
• Identify leak load
• Improve energy efficiency
• Plan future system upgrades