Air Leak Testing

Professional Air Leak Detection & Testing Services

Air leaks are the single largest source of wasted energy in compressed air systems. Studies consistently show that 20–30% of a compressor’s output is lost through undetected leaks in a typical industrial facility. At CompressorTech, our professional air leak testing service uses advanced ultrasonic detection technology to locate and quantify every leak in your system — delivering measurable energy savings and improved performance.

Why Air Leak Testing Matters

Compressed air is one of the most expensive utilities in any industrial facility, often costing more per unit of energy than electricity, gas, or water. Yet many businesses operate with significant air leaks that silently drain thousands of dollars each year. A single 3mm leak at 700 kPa can waste over $3,500 per year in electricity alone.

Beyond the direct energy cost, air leaks cause a cascade of problems:

• Pressure drops that reduce tool and equipment performance
• Compressor overwork leading to accelerated wear and breakdowns
• Production quality issues from inconsistent air pressure
• Increased maintenance costs as compressors run harder and longer
• Higher carbon emissions from excess energy consumption

Our Air Leak Testing Process

CompressorTech uses state-of-the-art ultrasonic leak detection equipment that can identify leaks as small as 0.5mm, even in noisy industrial environments. Our certified technicians follow a systematic process to ensure every leak is found, documented, and reported.

Step 1: Baseline Assessment — We begin by reviewing your compressed air system layout, operating pressures, and current energy consumption. This establishes a performance baseline against which savings will be measured.

Step 2: Ultrasonic Scanning — Our technicians systematically scan every component of your air distribution system, including pipe joints, couplings, hoses, valves, fittings, manifolds, FRL units (filter-regulator-lubricator), quick-connect fittings, and point-of-use connections.

Step 3: Leak Tagging & Quantification — Each leak is physically tagged with a unique identifier, and the estimated leak rate (in litres per minute) and annual cost is calculated. Leaks are prioritised by severity for efficient repair scheduling.

Step 4: Comprehensive Report — You receive a detailed report including a complete leak inventory with locations, photographs, leak rates, estimated annual cost per leak, total system leakage rate, projected savings from repairs, and prioritised repair recommendations.

What We Test

Our leak detection service covers your entire compressed air distribution system:

• Main distribution headers and branch lines
• Pipe joints, flanges, and threaded connections
• Valves, regulators, and pressure relief devices
• Quick-connect couplings and hose fittings
• Condensate drains (stuck-open drains are a major source of loss)
• Filter housings and separator bowls
• Point-of-use equipment connections
• Pneumatic cylinders and actuators

Typical Savings

Most facilities achieve a 20–50% reduction in compressed air energy costs after a professional leak detection and repair program. For a typical mid-sized manufacturing plant running a 75 kW compressor, this can equate to savings of $8,000–$20,000 per year. The service typically pays for itself within 2–4 weeks.

Industries We Support

Our air leak testing service is available to all industries across Australia, including manufacturing, food and beverage, automotive, mining and resources, pharmaceutical, packaging, and general industrial facilities. We also offer ongoing leak management programs with scheduled re-testing to ensure your system stays efficient over time.

Ready to stop wasting energy? Contact CompressorTech today for a professional air leak test. Call 0493 631 786 or request a free quote online.