How Compressed Air Audits Can Cut Costs and Boost Efficiency in Your Facility

If your operation relies on compressed air, you’re likely spending more than you need to—sometimes thousands of dollars more per year. That’s because most facilities lose 20–30% of their compressed air system energy through leaks, poor system design, or inefficient usage.

At Process & Power in Memphis, we specialize in comprehensive compressed air audits that help manufacturers across Tennessee, Arkansas, and Mississippi uncover waste, improve reliability, and lower utility bills. Whether you’re running a food processing plant, fabrication shop, or pharmaceutical line, an audit is one of the smartest, most cost-effective upgrades you can make.

What Is a Compressed Air Audit?

A compressed air audit is a detailed evaluation of your entire air system—from compressors and dryers to piping, filtration, and end-use equipment. Our goal is to find hidden inefficiencies and provide a data-backed plan for improving performance.

Our audits include:

• Leak detection and quantification

• Pressure mapping and drop analysis

• Airflow and CFM monitoring

• Power usage and cost tracking

• Demand-side analysis (tools, machines, operations)

• System layout and sizing review

Whether your system is too large, undersized, leaking air, or running at excessive pressure, we’ll find it—and show you how to fix it.

Why Compressed Air Systems Waste Energy

Compressed air is often called the “fourth utility” in industrial facilities, after electricity, gas, and water. But it’s usually the least efficient—and most neglected.

Here’s why:

🔹 Leaks Are Invisible

A single 1/8” leak can waste over $1,200 a year. Multiply that across multiple connections, and the loss can be staggering.

🔹 Oversized Systems

If your system is too large for your actual air demand, you’re burning electricity for air you don’t need.

🔹 Inefficient Piping Layout

Improper pipe sizes, long runs, or too many turns lead to pressure drops and wasted energy.

🔹 Poor Controls

Running compressors at higher-than-necessary PSI “just in case” is a common but expensive habit.

🔹 Neglected Maintenance

Dirty filters, oil saturation, and clogged drains all reduce system performance.

What You Can Save

After a professional audit, many customers reduce compressed air costs by 20% to 50%. You may also benefit from:

• Lower power bills

• Reduced compressor wear and tear

• Fewer breakdowns and unplanned downtime

• Extended system lifespan

• Better air quality

• Utility rebates for energy-saving improvements

We’ve seen customers in Memphis, Jackson, and Little Rock pay off the cost of an audit within weeks.

When Should You Get an Air Audit?

It’s smart to schedule a compressed air audit if:

• Your utility bills seem too high

• You’ve recently expanded operations or added equipment

• You haven’t inspected your system in over a year

• You’re planning to purchase a new compressor

• You’re struggling with pressure drops or air quality issues

• You want to meet sustainability or energy efficiency goals

Even if your system appears to be running fine, a compressed air audit may uncover hidden inefficiencies.

What Happens During an Audit?

At Process & Power, we tailor each audit to your facility's needs:

1. Consultation

We start by understanding your equipment, production process, and pain points.

2. On-Site Evaluation

We walk through your facility to inspect compressors, piping, filters, and end-use equipment.

3. Data Logging

We install monitors to track flow, pressure, and energy usage—typically over 7–10 days of normal operation.

4. Reporting

We analyze the data and provide a detailed report outlining inefficiencies, savings opportunities, and system upgrade recommendations.

5. Implementation

We help you act on the findings with upgrades, repairs, or new equipment—whatever makes sense for your goals and budget.

Common Problems We Uncover

Here’s what we often find during compressed air audits:

• Dozens of small leaks throughout the system

• Compressors running at 120 PSI when only 90 is needed

• Compressors operating simultaneously when only one is required

• Dirty filters and saturated dryers contaminating the air

• Long piping runs that cause major pressure drops

Correcting just one of these issues can make a big difference in cost and performance.

Industries We Serve

Process & Power has helped industrial operations across the Mid-South optimize compressed air systems, including:

• Food and beverage processors

• Pharmaceutical and life sciences facilities

• Metalworking and fabrication shops

• Automotive and aerospace manufacturers

• Plastics and molding companies

• Chemical and petrochemical plants

• Water and wastewater utilities

• Warehousing and logistics centers

Service Areas

We offer on-site audits and support for businesses in:

• Memphis & Jackson, TN

• Springdale & Little Rock, AR

• Tupelo, MS
  …and surrounding regions.

Whether you’re in a major metro or a rural plant, we’ll get boots on the ground and data in your hands fast.

Stop Wasting Money on Compressed Air

Compressed air is one of your most expensive utilities—make sure you’re not losing it to leaks and inefficiency.

📍 Process & Power • 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
🌐 www.processnpower.com

Let’s identify your savings and streamline your system today.