How to Reduce Pressure Drop in Industrial Compressed Air Systems
If your compressed air system feels like it’s constantly “working harder than it should,” pressure drop may be the reason.
Across Memphis, Jackson, Tupelo, Little Rock, and Springdale, many facilities unknowingly waste energy by compensating for pressure loss instead of correcting the root cause. Operators increase system pressure to keep tools running—but that forces compressors to consume more electricity and generate more heat.
In 2026, reducing pressure drop is one of the simplest ways to improve efficiency, extend equipment life, and lower operating costs.
Here’s how to identify and correct it.
What Is Pressure Drop?
Pressure drop occurs when compressed air loses pressure as it travels through the system.
It’s caused by resistance in:
Undersized piping
Long pipe runs
Excessive fittings
Corrosion buildup
Dirty filters
Clogged dryers
The more resistance in the system, the harder the compressor must work.
Why Pressure Drop Is Expensive
To compensate for pressure loss, many facilities raise system setpoints.
Every 2 PSI increase in operating pressure can increase energy consumption by roughly 1%.
In high-demand Memphis-area facilities, this small adjustment can translate into thousands of dollars per year in added electricity costs.
Common Causes of Pressure Drop in Mid-South Facilities
1. Undersized Piping
Older facilities often expand production without resizing piping.
Undersized lines restrict airflow, creating bottlenecks that:
Reduce pressure at point-of-use
Force compressors to operate at higher output
2. Excessive Fittings and Sharp Bends
Each elbow, tee, or coupling increases airflow resistance.
Over time, system modifications add fittings that weren’t part of the original design.
3. Corrosion and Rust
Humidity in West Tennessee and North Mississippi accelerates internal pipe corrosion.
Rust buildup:
Reduces internal pipe diameter
Increases resistance
Restricts airflow
Older steel piping systems are especially vulnerable.
4. Dirty Filters and Dryers
Clogged filters and overloaded dryers restrict airflow and increase system resistance.
In humid climates, filtration components may need more frequent replacement.
5. Long Pipe Runs Without Loop Design
Dead-end piping layouts common in older Memphis industrial buildings can create uneven pressure distribution.
Looped piping systems help equalize pressure and reduce drop.
Signs You Have a Pressure Drop Problem
Tools losing power at distance from compressor
Operators requesting higher system pressure
Inconsistent performance across production areas
Rising energy bills
Compressor running continuously
If pressure at the compressor differs significantly from pressure at the farthest point-of-use, drop is likely occurring.
How to Reduce Pressure Drop
Upgrade Piping Size
Increasing pipe diameter reduces airflow resistance.
This is often one of the most impactful long-term improvements.
Convert to a Loop System
Loop systems allow air to flow from multiple directions, stabilizing pressure across the facility.
Minimize Fittings
Replace unnecessary elbows and tees with smoother transitions whenever possible.
Replace Corroded Piping
Modern aluminum or stainless systems resist corrosion and maintain internal diameter.
Maintain Filters and Dryers
Routine maintenance prevents airflow restriction caused by clogged components.
Perform a System Audit
A professional compressed air audit measures pressure at multiple points and identifies loss areas.
Many Memphis-area facilities discover that pressure drop—not compressor capacity—is the real issue.
Why Reducing Pressure Drop Extends Equipment Life
Lower system pressure reduces:
Compressor strain
Operating temperature
Energy consumption
Mechanical wear
Stable pressure also improves tool performance and production consistency.
The Cost of Ignoring Pressure Drop
Unchecked pressure drop leads to:
Higher energy bills
Premature compressor wear
Increased maintenance
Production instability
Fixing the root cause is more cost-effective than constantly increasing system pressure.
Optimize Your Compressed Air System
Compressed air systems perform best when airflow is smooth, unrestricted, and balanced.
Reducing pressure drop:
Lowers energy use
Improves reliability
Extends equipment lifespan
Stabilizes production
Get a Professional Pressure Drop Evaluation
Process & Power supports facilities across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) with compressed air system evaluations designed to identify and reduce pressure drop.
📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
If your system pressure keeps creeping upward, pressure drop may be the hidden cost driving your energy bills.
