Compressed Air System Audits: What Memphis Manufacturers Should Expect
If your facility’s energy bills keep climbing, pressure seems inconsistent, or compressors run harder than they should, it may be time for a compressed air system audit.
Across Memphis, Jackson, Tupelo, Little Rock, and Springdale, many manufacturers assume their compressor is the issue—when in reality, the inefficiencies often exist elsewhere in the system.
In 2026, with tighter margins and rising electricity costs, a professional compressed air audit is one of the smartest operational investments a facility can make.
What Is a Compressed Air System Audit?
A compressed air audit is a comprehensive evaluation of your entire air system—not just the compressor.
It examines:
Air demand (CFM usage over time)
Pressure stability and setpoints
Leak rate
Energy consumption
Piping design and pressure drop
Dryer and filtration performance
Control strategy and sequencing
The goal is simple: identify inefficiencies, quantify losses, and provide a clear plan to improve performance.
Why Memphis Facilities Benefit From Audits
Mid-South facilities face unique conditions:
High humidity that increases moisture load
Long, hot summers that stress compressors
Older industrial buildings with dated piping layouts
Expanded production without updated air infrastructure
These regional factors often create inefficiencies that go unnoticed until energy costs spike or failures occur.
Step 1: Load Profile Analysis
One of the first things evaluated in an audit is your compressor load profile.
This shows:
How much air your facility actually uses
When peak demand occurs
Whether compressors are properly sized
How often systems run unloaded
Many Memphis-area facilities discover their compressors are oversized, undersized, or improperly staged—each scenario wastes energy.
Step 2: Leak Detection and Quantification
Leaks are one of the largest hidden expenses in compressed air systems.
A professional audit uses ultrasonic detection and performance data to:
Identify leak locations
Estimate total leak percentage
Calculate annual energy loss
It’s not uncommon for facilities to discover that 20–30% of produced air is lost to leaks.
Step 3: Pressure Drop Evaluation
Pressure drop across piping systems forces compressors to work harder.
An audit examines:
Main header sizing
Branch line restrictions
Excessive fittings or elbows
Corrosion buildup
Dead-end piping design
Many older facilities around Memphis industrial corridors have piping layouts that were never redesigned after expansion.
Step 4: Dryer and Moisture Control Assessment
In humid regions like West Tennessee and North Mississippi, moisture management is critical.
An audit reviews:
Dryer sizing relative to CFM demand
Inlet air temperature
Dew point performance
Filter condition
Condensate management
Improper dryer sizing often causes corrosion, tool damage, and product quality issues.
Step 5: Control Strategy Review
Modern compressed air systems require smart control logic.
An audit evaluates:
Compressor sequencing
Pressure band settings
Variable Speed Drive (VSD) integration
Redundant system coordination
Poor sequencing often leads to multiple compressors running unnecessarily—driving up energy costs.
What You Receive After an Audit
A thorough audit provides:
A clear summary of inefficiencies
Quantified energy waste estimates
Cost-saving recommendations
Suggested system improvements
ROI projections for upgrades
Instead of guessing, you gain data-backed decisions.
Common Findings in Mid-South Facilities
Facilities in Memphis and surrounding areas frequently discover:
Oversized compressors running inefficiently
Undersized piping causing pressure drop
Elevated system pressure masking leak issues
Poor ventilation contributing to overheating
Excessive unloaded run time
Each of these directly impacts energy cost and equipment lifespan.
How Audits Improve Reliability
Beyond energy savings, audits also improve uptime by:
Reducing overheating risk
Lowering mechanical strain
Improving pressure stability
Extending equipment life
Preventing emergency failures
Facilities that complete audits typically see fewer unexpected shutdowns.
When Should You Schedule an Audit?
You should consider a compressed air audit if:
Energy bills have increased
Production demand has changed
New equipment has been added
Compressors run nearly nonstop
Moisture issues persist
You’re planning an equipment upgrade
Audits are especially valuable before investing in new compressors.
Why Local Experience Matters
Facilities searching for compressed air system audit near me benefit from working with teams who understand:
Regional climate challenges
Memphis-area industrial infrastructure
Typical facility expansion patterns
Local production demands
A regional perspective ensures recommendations reflect real-world operating conditions.
Get a Clear Picture of Your Compressed Air System
If your compressed air system feels inefficient—or you simply want confirmation that it’s optimized—an audit delivers clarity.
Process & Power supports manufacturers across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) with professional compressed air system audits designed to reduce energy costs and improve reliability.
📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
A data-driven evaluation today can prevent costly surprises tomorrow.
