5 Signs Your Industrial Air Compressor Is Undersized for Your Facility
Many compressor problems aren’t caused by failure—they’re caused by improper sizing.
As facilities grow, add equipment, or expand production, compressed air demand increases. If the original compressor was sized for yesterday’s needs, it may struggle to keep up today.
Here are five clear warning signs your compressor may be undersized.
1. Pressure Drops During Peak Production
If operators report tools losing power or automation lagging during busy shifts, your system may lack sufficient CFM capacity.
Raising pressure to compensate only increases strain and energy costs.
2. Compressor Runs Nearly Nonstop
Compressors should not operate at 100% load constantly.
Continuous full-load operation:
Increases heat
Accelerates wear
Reduces lifespan
An undersized compressor has no margin for demand spikes.
3. Frequent High-Temperature Alarms
When compressors operate at maximum capacity continuously—especially in humid Mid-South climates—overheating becomes common.
This often signals inadequate capacity.
4. Growing Energy Bills Without Increased Production
An undersized compressor works harder to meet demand, increasing electricity usage.
Higher bills without increased output often indicate capacity issues.
5. Expansion Has Occurred Without System Review
Adding:
New packaging lines
Pneumatic tools
Automation equipment
Without reassessing compressed air demand is one of the most common causes of undersized systems.
The Cost of Undersizing
Undersized systems lead to:
Higher maintenance costs
More emergency repairs
Shorter equipment life
Production instability
In many cases, adding a properly sized supplemental compressor is more cost-effective than running an overloaded unit to failure.
Compressed Air System Audits: What Memphis Manufacturers Should Expect
Many facilities suspect inefficiency—but don’t know where it’s coming from.
A compressed air system audit provides a clear, data-driven understanding of system performance.
What a Professional Audit Includes
A comprehensive audit evaluates:
Compressor load profile
Energy consumption trends
Leak rate
Pressure drop across piping
Dryer performance
Control strategy
This provides measurable data—not guesswork.
Why Audits Deliver High ROI
Audits often uncover:
Oversized compressors running inefficiently
Undersized piping causing pressure drop
Leaks wasting 20–30% of output
Poor pressure control strategies
Correcting these issues can significantly reduce operating costs.
Memphis-Specific Considerations
Facilities in the Mid-South must account for:
High humidity
Seasonal temperature swings
Older industrial infrastructure
Extended operating hours
A local audit factors in these real-world conditions.
Oil-Free vs. Oil-Flooded Air Compressors: Which Is Right for Your Industry?
Choosing between oil-free and oil-flooded compressors depends on application—not preference.
Oil-Flooded Compressors
These are common in most industrial facilities because they:
Provide efficient cooling
Offer strong reliability
Deliver lower upfront cost
Ideal for general manufacturing, logistics, and fabrication.
Oil-Free Compressors
Oil-free compressors are used when air purity is critical, such as:
Food processing
Pharmaceutical manufacturing
Medical applications
Sensitive electronics
They eliminate the risk of oil contamination in the air stream.
Which Is Right for Your Facility?
The right decision depends on:
Industry regulations
Air purity requirements
Budget considerations
Long-term operating costs
Get Expert Guidance
Process & Power supports facilities across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) with compressed air system evaluation, equipment selection, and full-service support.
📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
Whether you're evaluating Ingersoll Rand VSD systems, addressing sizing concerns, scheduling a system audit, or choosing between oil-free and oil-flooded compressors, expert guidance ensures the right long-term solution.
