Compressed air is often the most expensive utility in a workshop, and the least monitored. The compressor runs, air reaches the tools, so everything looks fine. A compressed air audit shows what is really happening: how much air you produce, how much you lose, and what it costs you.
This service is offered for sites in France. If your site is elsewhere, contact us first and we will look at what is possible.
Why audit your compressed air system
- Energy: over the life of a compressor, electricity is by far the largest share of its total cost, well ahead of purchase price and maintenance. Every improvement shows up on the power bill.
- Leaks: in poorly maintained networks, leaks often account for a significant share of the air produced. They keep the compressor running for nothing, including at night and at weekends.
- Pressure set too high: running above the real need costs energy every operating hour and increases leak flow.
- Air quality: water or oil in the network, an undersized dryer, clogged filters. The result is paint defects, damaged tools and downtime.
- Air receiver and inspections: a poorly sized receiver makes the compressor start too often, and every receiver has to follow its regulatory inspections.
Three audit levels, depending on your needs
A compressed air audit does not have to be a big operation. We work in steps, and each level tells you whether it is worth going further.
Level 1: the preliminary check
A visit to the compressor room and a first walk around the network. We record the hour meters (total and loaded hours), compressor power, set pressure and the condition of drains and air treatment. You get a first estimate of your electricity use, likely losses and savings potential.
Level 2: one week of measurement
Data loggers are fitted on each compressor and on the network for a full production week, weekend included: electrical power, loaded and unloaded time, pressure. The hour-by-hour air demand profile shows what a quick check can only guess: peaks, quiet periods, air used at night and at weekends (often leaks). We then simulate the possible solutions, such as a variable speed machine, using your own figures.
Level 3: the full system audit
An audit of the whole chain, from supply to use, following the approach of ISO 11011 (energy efficiency assessment of compressed air systems):
- supply: compressor efficiency, control, cooling, heat recovery;
- treatment and distribution: dew point and air quality to ISO 8573-1, pressure drop across dryers, filters and pipework, pressure actually available at each point of use;
- demand: ultrasonic leak detection with each leak tagged and its flow estimated, inappropriate uses (blow guns left open, cooling with compressed air), real pressure needs of each workstation.
A full audit report can also support an ISO 50001 approach and grant applications that require a prior study.
What we look at
- Your machines: models, power ratings, age, operating hours and loaded hours.
- Your consumption profile: air flow demand through the day, peaks, quiet periods, air use outside production hours.
- Network pressure: set pressure, pressure actually available at the point of use, pressure drop in the pipework.
- Leak detection: fittings, hoses, quick couplers, drains, tools. Leaks are located and ranked by size.
- Air quality and drying: dryer type, filtration, water at points of use, compared with what the air is used for (painting, tools, process).
- Condensate drains: forgotten manual drains, timed drains that waste air.
- Compressor room and ventilation: temperature, air intake, hot air extraction, access for maintenance.
- Heat recovery: the heat produced by a screw compressor can sometimes be used to heat a room or water.
What you receive
A clear written report with:
- findings, area by area;
- a list of actions ranked by priority, starting with low-cost ones (fixing leaks, lowering pressure, isolating the network outside production hours);
- an estimate of possible savings for each action, based on your readings and your electricity price;
- where useful, a recommendation for a machine suited to your consumption profile.
The audit comes with no obligation to buy. If your installation is correctly sized, the report will say so.
When air demand varies a lot
A fixed-speed compressor cycles between loaded running, idling and stopping. If your consumption changes sharply from hour to hour or day to day, the S 220 PM, a 22 kW screw compressor with a permanent magnet motor and variable speed, matches its speed to the air flow demanded. The audit is a way to confirm or rule out this option with figures.
How it works
- Your request: fill in the form on this page or use the contact page.
- A discussion to understand your installation: number of machines, how the air is used, working hours, problems you have noticed.
- A visit or readings: depending on your situation, our technicians or a partner dealer in your area visit your site, or we work from readings you send us (photos, hour meters, pressures).
- The report: we go through it with you and answer your questions.
Price: on quotation. Each audit level is a paid service. The price depends on the level chosen, the number of compressors and the size of the network: you receive the quotation after the first discussion, before any commitment.
First steps you can take yourself
Before the audit, you can already estimate what is at stake:
- put a cost on your losses with the compressed air leak cost calculator;
- estimate your compressor's power bill with the electricity cost calculator and read our guide to compressor energy costs;
- walk round the workshop when production is stopped, following our article on how to detect and repair compressed air leaks;
- check your pipework with our guide to a leak-free compressed air network;
- review your obligations with our guide to air receiver regulations.
Grants and incentives
Some energy efficiency work on compressed air systems may qualify for financial support. See our page on energy efficiency grants to find out what may apply to your project.