Air System Audits

Comprehensive Compressed Air System Audits

Is your compressed air system costing more than it should? At CompressorTech, our professional air system audits provide a complete, data-driven analysis of your entire compressed air installation — from generation through treatment and distribution to point-of-use. We identify inefficiencies, quantify waste, and deliver actionable recommendations that typically save our clients 20–50% on energy costs.

Why Audit Your Compressed Air System?

Compressed air is often called the “fourth utility” in industrial facilities, yet it is by far the most expensive to produce. Generating compressed air uses approximately 8 times more electricity than the equivalent energy delivered. This makes it critical to ensure every kilowatt is being used efficiently.

Common issues we find during audits include:

• Oversized compressors running at partial load with poor efficiency
• Pressure set too high — every 1 bar of unnecessary pressure wastes 7% of energy
• Poor compressor sequencing causing multiple machines to run inefficiently
• Inadequate or missing air treatment leading to moisture damage and product contamination
• Distribution losses from undersized piping, excessive bends, and dead legs
• Air leaks that waste 20–30% of total compressed air output
• Inappropriate use of compressed air for tasks better served by other technologies

Our Audit Methodology

CompressorTech audits follow a rigorous engineering methodology aligned with Australian best practices and international standards. Our audits are conducted by experienced compressed air engineers, not salespeople.

Phase 1: Data Logging & Measurement — We install precision data loggers on your compressors, treatment equipment, and distribution system. These devices record pressure, flow, power consumption, temperature, and dew point at frequent intervals over a minimum 7-day period, capturing your full range of operating conditions including shift changes, weekends, and production peaks.

Phase 2: System Inspection — While data loggers are running, our engineers physically inspect every component of your compressed air system. This includes compressor condition, air treatment equipment (dryers, filters, condensate drains), storage receivers, distribution piping layout, and point-of-use connections.

Phase 3: Air Leak Survey — Using ultrasonic detection equipment, we identify and tag every air leak in your system. Each leak is quantified in litres per minute and the estimated annual cost is calculated.

Phase 4: Analysis & Reporting — Our engineers analyse all collected data to produce a comprehensive audit report. This includes demand profiling, compressor performance analysis, system efficiency calculations, specific power (kW/m³/min) benchmarking, and identification of all improvement opportunities.

What You Receive

Our audit report is a thorough, professionally presented document that includes:

• Executive summary with headline findings and total savings opportunity
• Detailed system description and schematic
• Demand profile analysis showing actual air consumption patterns
• Compressor performance data and efficiency benchmarking
• Air treatment system assessment
• Distribution system evaluation
• Complete air leak survey results
• Prioritised list of improvement recommendations with estimated costs and payback periods
• Energy savings calculations with ROI projections
• Capital expenditure options with finance scenarios

Return on Investment

Compressed air system audits deliver some of the highest ROIs of any energy efficiency measure. Our clients typically see audit recommendations pay for themselves within 6–18 months, with ongoing savings continuing year after year. A typical 100 kW compressed air system can save $15,000–$40,000 annually after implementing audit recommendations.

When Should You Audit?

We recommend a compressed air system audit if any of the following apply:

• Your compressed air energy costs seem higher than expected
• You’ve never had a professional system audit
• Your production demands or facility layout have changed significantly
• You’re experiencing pressure issues, moisture problems, or frequent breakdowns
• You’re considering purchasing new compressor equipment
• You want to meet sustainability or carbon reduction targets

Book your compressed air system audit today. Call CompressorTech on 0493 631 786 or request a quote online. We service all Australian states and territories.