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Air End
Repair

Compressed
Air Leak Audits

System
Design

Technical
Service

AIRTILITY
program

Compressed
Air Audit Services

Remote
Monitoring

Compressed Air Leak Audits

Energy Efficiency & Leak Detection

Compressed air leaks are one of the largest sources of wasted energy in industrial facilities throughout the Northeast. COMAIRCO’s compressed air leak audit services help manufacturers, food processors, pharmaceutical facilities, automotive suppliers, utilities, and other industrial operations identify hidden air losses, reduce energy consumption, and improve compressed air system reliability.

Air Leak Audits

Compressed Air Leak Audits for Northeast Manufacturers

From New York and Pennsylvania to New Jersey, New Hampshire, Massachusetts, Maine, and West Virginia, industrial facilities rely on compressed air for production, automation, packaging, assembly, and process applications. Even a well-maintained compressed air system can develop leaks that increase operating costs and reduce system efficiency. COMAIRCO helps facilities throughout the Northeast identify and prioritize leak repairs using advanced ultrasonic leak detection technology and compressed air leak management best practices.

Industries We Serve

  • Manufacturing
  • Food & Beverage
  • Pharmaceutical
  • Plastics
  • Automotive
  • Aerospace
  • Chemical Processing
  • Metal Fabrication
  • Electronics
  • Wastewater Treatment
  • Pulp & Paper
  • Energy & Utilities
COMAIRCO technician wearing a hard hat, safety glasses, hearing protection, and a high-visibility safety vest using an ultrasonic leak detector in an industrial compressed air system.Image generated with Microsoft Copilot for COMAIRCO.

Why Perform a Compressed Air Leak Audit?

Compressed air systems naturally develop leaks over time at fittings, hoses, couplings, valves, regulators, filters, and production equipment. Without a structured leak management program, these losses can represent a significant percentage of total compressed air consumption.
An ultrasonic leak audit helps:

  • Reduce energy consumption
  • Lower operating costs
  • Improve system reliability
  • Reduce compressor run time
  • Extend equipment life
  • Improve system pressure stability
  • Support sustainability initiatives

What Is Included in a Leak Audit?

Our compressed air leak audits typically include:

  • Facility walk-through
  • Ultrasonic leak detection survey
  • Leak tagging and identification
  • Estimated leak flow calculations
  • Annual energy cost estimates
  • Prioritized repair list
  • Summary report
  • Follow-up recommendations

How Ultrasonic Leak Detection Works

Compressed air leaks generate high-frequency sound waves that are typically inaudible to the human ear. COMAIRCO technicians use specialized ultrasonic leak detection equipment to locate leaks while your facility remains in operation.
Each leak is:

  • Identified
  • Tagged
  • Documented
  • Quantified
  • Prioritized for repair

The final report provides actionable recommendations that help maintenance teams focus on the costliest leaks first.

Compressed air leak audit report showing an identified air leak on industrial piping with estimated annual energy cost, tag number, location, and repair notes.Image courtesy of COMAIRCO.

How Much Can Compressed Air Leaks Cost?

In many Northeast manufacturing facilities, compressed air systems operate 24 hours per day. Even a small leak can waste thousands of dollars annually in electricity costs and increase compressor run time. Multiple undetected leaks can significantly impact plant energy consumption and production efficiency.

A structured leak management program can help facilities maintain leak losses below acceptable targets and continuously improve compressed air system efficiency.

A 1/4-inch compressed air leak can cost thousands of dollars annually in wasted electricity, depending on operating pressure, run time, and local utility rates. Identifying and repairing leaks is often one of the fastest-return energy efficiency projects available in an industrial facility.

Compressed air leak cost chart showing estimated annual energy costs for 1/16-inch, 1/8-inch, and 1/4-inch leaks at 100 psi, including flow rates in CFM and annual operating costs.Chart courtesy of COMAIRCO.

Compressed Air Leak Size Cost Examples

Common Sources of Compressed Air Leaks

Leaks are commonly found at:

  • Quick-connect fittings
  • Flexible hoses
  • Pipe joints
  • Valves
  • Regulators
  • Air dryers
  • Filters
  • Condensate drains
  • Pneumatic tools
  • Production equipment

Many facilities are surprised to learn that numerous small leaks can cost more than a single large leak.

Leak Audits and Compressed Air Audits

Compressed air leak audits are often performed alongside data-logged compressed air audits.
Combining both services allows facilities to:

  • Measure demand
  • Analyze system pressure
  • Evaluate compressor performance
  • Identify leak load
  • Improve energy efficiency
  • Plan future system upgrades

Schedule a Compressed Air Leak Audit

COMAIRCO helps manufacturers identify hidden energy losses through professional ultrasonic leak detection and compressed air audit services. Our team can help you implement an effective leak management program, prioritize repairs, and improve overall system efficiency.

Contact COMAIRCO today to schedule a compressed air leak audit.

Industrial compressors

With more than 40 years of experience, Comairco is a true leader in North America.

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Used equipment

We have a wide range of air compressors, air dryers, tanks

and outdoor mobile stations designed for your air compressors,

as well as other used products in order

to help you out in emergency situations.

 

 

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Compressed Air Services

COMAIRCO offers an emergency compressed air maintenance and compressors maintenance service, 24 hours a day, 7 days a week. Our technicians are available around the clock to perform compressed air installation and compressors installation or repairs.

Find out more Camion Comairco