Why Air System Efficiency Is the Most Overlooked Opportunity in Industrial Energy Savings

In the world of industrial operations, compressed air systems are often described as the "fourth utility" alongside electricity, water, and gas. They're vital for powering tools, controlling processes, and maintaining automation. Yet despite this importance, compressed air systems are among the most commonly neglected when it comes to energy optimisation. At Technical Air Systems (TAS), we've seen time and again how system efficiency is not just a technical issue, but a business one.

The Hidden Cost of Inefficiency

Most businesses don't realise that up to 30% of compressed air can be lost through leaks, poor pipework, and incorrect pressure settings. Even more can be wasted due to oversized or improperly configured compressors. This translates directly to higher energy bills and reduced system reliability.

Every kilowatt of energy used to generate compressed air comes at a cost. When that air is leaking out of joints, underused during idle times, or forcing your compressor to cycle excessively, it’s your bottom line that suffers. Worse still, these inefficiencies often go unnoticed until there is a major failure or the energy bill becomes unmanageable.

What Does "Efficiency" Really Mean?

Efficiency in compressed air systems isn’t just about cutting consumption. It means designing a system that delivers stable pressure, uses energy only when needed, and lasts longer thanks to proper maintenance. True efficiency is achieved when:

• Compressors are sized and specified correctly for your demand profile

• Pressure drops are eliminated through smart pipework layout

• Filtration and drying equipment are matched to application needs

• Leaks are proactively monitored and addressed

And perhaps most importantly, efficiency means predictability — your system performs consistently day in, day out.

Small Changes, Big Impact

Improving system efficiency doesn't require a full plant overhaul. In fact, some of the most effective improvements are simple:

• Leak detection and repair: Fixing air leaks can deliver immediate savings

• Pressure audits: Reducing system pressure by just 1 bar can cut energy use by 7%

• Right-sizing: Avoiding oversized compressors that run inefficiently

• Smart controls and VSDs: Compressors that adapt to your actual demand

• Scheduled maintenance: A well-serviced machine works harder for longer

At TAS, our AirSure service plans are built around keeping your system at peak performance – not just reacting to breakdowns. That means fewer callouts, lower operating costs, and extended equipment life.

Data Logging: Make the Invisible Visible

The challenge with air system inefficiency is that you often can't see it. That's where data logging comes in.

We install temporary or permanent logging devices that track pressure, flow, and energy usage over time. This reveals your system’s actual behaviour – not just what you think it’s doing. You may find compressors are running when they shouldn’t be, or that pressure drops spike during production surges.

Armed with this data, TAS engineers can recommend targeted changes with measurable ROI. It also gives you audit-ready evidence for energy-saving initiatives or ESOS compliance.

Conclusion: Efficiency Is a Competitive Advantage

Compressed air efficiency isn’t just a technical win – it’s a strategic one. Lower energy bills, more reliable operations, and longer equipment life all contribute to improved productivity and profitability.

At TAS, we help our clients see beyond the compressor and into the full air system. From system design to servicing, we build and maintain solutions that work better – for longer.

Ready to unlock your system’s potential? Contact us for a data logging assessment or speak to us about AirSure service plans tailored to your site.