How to Detect Compressed Air Leaks Before They Impact Production

Compressed air leaks are one of the most expensive—and most overlooked—problems in industrial facilities.

Across Memphis, Jackson, Tupelo, Little Rock, and Springdale, manufacturers often assume their compressor is “working harder than usual.” In reality, the system may be compensating for leaks that are quietly wasting energy and reducing pressure stability.

In 2026, with higher utility rates and tighter margins, finding and fixing leaks early is one of the fastest ways to cut operating costs.

Here’s how to detect compressed air leaks before they disrupt production.

Why Air Leaks Are So Expensive

Leaks force compressors to:

• Run longer

• Operate at higher pressure

• Consume more electricity

• Experience greater wear

In many Mid-South facilities, 20–30% of compressed air output is lost to leaks.

That wasted air translates directly into wasted energy—and rising utility bills.

Common Places Leaks Occur

Leaks often develop at:

• Quick-connect fittings

• Hose connections

• Couplings

• Valves

• Regulators

• Threaded pipe joints

• Drain traps

• Flexible lines

Older facilities around the Memphis industrial corridor are particularly prone to connection-related leaks due to system expansion over time.

Early Warning Signs of Air Leaks

Before production is affected, you may notice:

• Compressors running longer than normal

• Increased unloaded run time

• Rising energy bills without increased output

• Pressure drops during peak demand

• Tools losing power intermittently

If your system pressure is creeping upward to compensate, leaks may be the cause.

Method 1: The Basic “Listen Test”

In quiet areas of your facility:

• Walk the air lines

• Listen for hissing sounds

• Check fittings and connections

This simple method can identify larger leaks quickly—but smaller leaks are harder to detect by ear.

Method 2: Soapy Water Testing

Applying a soap solution to fittings and joints can reveal leaks through visible bubbling.

While effective for accessible areas, this method:

• Is time-consuming

• Doesn’t detect hidden leaks

• Isn’t practical for large facilities

Method 3: Ultrasonic Leak Detection (Most Effective)

Professional leak detection uses ultrasonic equipment to detect high-frequency sound waves generated by escaping compressed air.

Benefits include:

• Identifying small leaks

• Detecting leaks in noisy environments

• Locating hidden leaks above ceilings or behind equipment

• Quantifying leak size and energy loss

For large facilities in West Tennessee and North Mississippi, ultrasonic detection provides measurable data and ROI analysis.

Why Leaks Increase in the Mid-South

Humidity plays a role.

High moisture levels contribute to:

• Corrosion at joints

• Seal degradation

• Rust buildup

• Thread damage

Over time, this accelerates leak formation—especially in older piping systems.

The Hidden Cost of “Small” Leaks

A single small leak may seem insignificant—but multiple small leaks add up quickly.

Even a 1/8-inch leak can cost thousands of dollars annually in wasted energy.

Multiply that across an entire facility, and the financial impact becomes substantial.

Why Fixing Leaks Improves More Than Energy Costs

Leak reduction also:

• Stabilizes system pressure

• Reduces compressor run time

• Extends equipment lifespan

• Lowers maintenance frequency

• Reduces overheating risk

In many cases, fixing leaks improves overall system reliability.

How Often Should You Perform Leak Detection?

Facilities running multiple shifts or continuous production should consider:

• Annual professional leak audits

• Quarterly internal inspections

• Immediate checks after system modifications

Regular monitoring prevents leaks from compounding over time.

When to Schedule a Professional Leak Audit

Consider scheduling an audit if:

• Energy bills are rising

• Compressors run constantly

• Pressure instability is common

• System upgrades are being planned

• Equipment is aging

A professional audit provides measurable savings projections—not guesswork.

Reduce Energy Waste Before It Impacts Production

Compressed air leaks don’t fix themselves. The longer they go undetected, the more they cost.

Process & Power provides compressed air system leak detection and energy audits for facilities across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR).

📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500

If your compressed air system seems inefficient or unstable, leak detection may be the fastest way to improve performance and reduce operating costs.