Nashville Case Study: Extending Compressor Life with Preventative Maintenance
In Nashville’s fast-moving industrial sector, compressed air is often called the “fourth utility.” From powering hand tools to supporting robotic automation, running packaging lines, and keeping production reliable, compressed air is essential across industries like automotive supply, food processing, and healthcare manufacturing.
But with this reliance comes cost — not just in energy, but also in the risk of breakdowns. Too many facilities take a “run-to-failure” approach, waiting until a compressor goes down before calling for service. This leads to expensive downtime, high repair costs, and equipment that wears out years earlier than it should.
A smarter approach is preventative maintenance — and one Nashville manufacturer recently proved just how much of a difference it makes.
The Facility: A Nashville Metal Fabrication Plant
A mid-sized metal fabrication plant in Davidson County depended on three rotary screw compressors to power tools, robotic welders, and cutting equipment. Running nearly nonstop, these compressors were the backbone of production.
For years, maintenance was neglected. Filters weren’t changed until clogged, oil changes were skipped, and leaks went unrepaired. Over time, the impact became impossible to ignore:
Compressors overheated regularly
Air pressure dropped during peak demand
Energy bills climbed month after month
Downtime averaged 8–10 hours per month
Management realized they were heading toward costly early replacements and unsustainable operating costs.
The Problem: Compressors at Risk of Failure
An assessment revealed several problems:
Clogged filters restricted airflow
Contaminated oil caused bearing wear
Air leaks wasted thousands of dollars in electricity
Loose belts created vibration and efficiency loss
One unit, less than 10 years old, was already showing signs of premature failure.
The Solution: Preventative Maintenance
Process & Power developed a tailored preventative maintenance plan that addressed both immediate issues and long-term reliability.
Routine Inspections – Quarterly checks of filters, belts, lubrication, and system performance
Oil and Filter Changes – Scheduled changes to protect bearings and prevent overheating
Leak Detection – Ultrasonic testing revealed and repaired over 20 leaks
Alignment and Tensioning – Belts and couplings adjusted for smoother operation
Monitoring – Tracking pressures and flows to catch issues before they caused downtime
The Results: Reliability Restored
Within six months, the plant saw dramatic improvements:
Downtime dropped 75% – Production interruptions were nearly eliminated
Energy costs fell 18% – Leak repairs and optimized performance cut waste
Equipment life extended – Compressors once at risk are now projected to run another 8–10 years
Capital expense avoided – The plant postponed the need for a $60,000 replacement unit
The preventative program paid for itself quickly, saving tens of thousands of dollars in lost production and energy waste.
Why Preventative Maintenance Matters
This case highlights why preventative care is essential for Nashville facilities:
Protects equipment investment – Compressors can last 15–20 years with proper care
Reduces energy waste – Eliminating leaks and inefficiencies saves thousands annually
Minimizes downtime – Planned service prevents unplanned breakdowns
Improves reliability – Operators can trust consistent air supply
Creates predictable budgets – Avoids unexpected repair and emergency costs
Nashville’s Local Challenges
Facilities in Middle Tennessee face conditions that make compressor care even more critical:
High humidity increases moisture risk in compressed air lines
Seasonal temperature swings affect oil viscosity and seals
Heavy production demand in industries like automotive and healthcare leaves little room for downtime
Preventative maintenance programs tailored to these conditions ensure year-round reliability.
Other Local Examples
Food Processor – A Nashville food plant struggled with frequent dryer failures. Preventative maintenance reduced downtime to near zero and improved product quality with cleaner, drier air.
Healthcare Supplier – A medical device manufacturer cut compressed air waste by 25% through leak detection and filter maintenance, saving over $30,000 annually.
How Nashville Facilities Can Get Started
Schedule an Assessment – Evaluate your current system health and risks
Develop a Plan – Set service intervals matched to workload and environment
Train Operators – Teach staff to recognize warning signs early
Track Performance – Monitor downtime, energy use, and costs to measure ROI
Review Annually – Adjust maintenance schedules as production needs evolve
The Role of Predictive Maintenance
Some facilities are also adding predictive strategies on top of preventative care:
Vibration analysis to detect bearing issues early
Thermography to identify electrical hot spots
Real-time monitoring to flag pressure and flow changes
By combining preventative and predictive approaches, Nashville manufacturers are maximizing uptime and efficiency.
Why Partner with Process & Power
Process & Power supports Nashville industries with:
A local presence for quick response
Factory-trained technicians who specialize in rotary screw and oil-free compressors
Complete care — from inspections to repairs, upgrades, and monitoring
Customized maintenance programs built for your industry
With Process & Power as your partner, you protect your investment and keep your compressed air system performing at its best.
Final Thoughts
Compressed air is too vital to leave to chance. For Nashville facilities, preventative maintenance is the key to longer compressor life, lower energy bills, and fewer costly breakdowns.
This case study proves it: with a structured program, one manufacturer avoided a premature replacement, saved more than $60,000, and secured reliable compressed air for years to come.
If your facility depends on compressed air — and most do — preventative maintenance isn’t just smart. It’s essential.
📍 Process & Power
1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
🌐 www.processnpower.com
