Compressed Air Audit Services

What Is a Compressed Air Audit?

A compressed air audit is a systematic evaluation of your compressed air system designed to identify inefficiencies and improvement opportunities. Audits may include leak detection, pressure and flow measurement, data logging, system analysis, and recommendations for improving efficiency, reliability, and performance.

The U.S. Department of Energy estimates that up to 50% or more of the energy required to run a 100 HP air compressor is wasted.

Serving Industrial Facilities Across Pennsylvania and Eastern Ohio

COMAIRCO provides compressed air audit services for facilities throughout Western Pennsylvania, Northwestern Pennsylvania, North Central Pennsylvania, and Eastern Ohio. Whether you operate a steel mill in the Pittsburgh region, a manufacturing facility in Erie or Youngstown, a natural gas operation serving the Marcellus or Utica shale plays, a forest products business near Warren or Bradford, a chemical processing facility, or a food processing and distribution operation, our team can help identify opportunities to improve compressed air system performance, reduce energy consumption, and lower operating costs.

Benefits of a COMAIRCO Compressed Air Audit:

• Reduce operating costs by 25% to 50%
• Cut maintenance costs by 10% to 80%
• Obtain the most accurate data on your system’s current performance
• Receive comprehensive documentation on power usage and system interrelationships
• Conduct the audit without any downtime or disruption to productivity
• Identify projects that may qualify for utility energy incentives available throughout Pennsylvania and Ohio, reducing upfront costs

Additionally, we offer three levels of air system audits, all aligned with Department of Energy standards—providing tailored solutions to meet your specific needs.

Comairco’s compressed air audits thoroughly evaluate your entire compressed air system to identify opportunities to maximize efficiency, reduce waste, and lower energy, maintenance, and equipment costs. These audits provide precise, data-driven insights into your system’s current condition—empowering you to optimize your system’s performance throughout Pennsylvania and Eastern Ohio’s manufacturing, energy, and industrial sectors.

A compressed air audit conducted by Comairco’s team of certified auditors is the most effective way to maximize your system’s efficiency. Designed to identify energy-saving opportunities, a compressed air energy audit often uncovers simple yet impactful solutions—such as minor piping adjustments, cost-effective compressor control tweaks, or adding storage capacity paired with precision flow controllers. Every compressed air system is unique, and our audits are tailored to address your specific needs for optimal performance.

Often, compressed air audits reveal enough savings to allow compressors to be turned off entirely. These audits can be integrated into existing maintenance contracts, enabling regular re-assessments as your facility, systems, environment, and compressed air requirements evolve over time.

Phase 1: Advanced Tool Deployment

We connect data loggers to critical points across your system.

• Pressure Sensors: Track localized pressure drops and stability fluctuations.
• Flow Meters: Measure actual air consumption throughout the distribution lines.
• Power Meters: Record continuous energy draw from your air compressor units.

Phase 2: Real-Time Performance Baselining

Our data logging instruments record live metrics with zero interruption to your daily production.

• CFM Tracking: Captures actual airflow utilization spikes across varying shifts.
• Energy Profiling: Logs real-time electrical power consumption against systemic demand.
• Pressure Profiling: Documents system pressure behavior during peak and low-use hours.

Phase 3: Demand Pattern Analysis

Our engineering team compiles the logged telemetry data to uncover hidden system behavior.

• Fluctuation Identification: Isolates operational gaps where air supply mismatches demand.
• Inefficiency Pinpointing: Tracks exact locations of severe air leaks and artificial demand.
• Control Evaluation: Assesses if current compressor controls are properly configured.

Phase 4: Control Strategy & Optimization

We use the finalized baseline profile to develop custom control strategies.

• Targeted Adjustments: Outlines exact recommendations to improve overall plant efficiency.
• Validation Planning: Sets an accurate performance metric to verify future energy savings.

Schedule a Compressed Air Audit in Pennsylvania and Eastern Ohio

Whether you operate a steel processing facility, manufacturing plant, natural gas operation, chemical processing facility, forest products business, food processing plant, distribution center, or industrial production site, COMAIRCO can help uncover opportunities to reduce energy costs and improve compressed air system performance through a professional audit.

Frequently Asked Questions

How much energy can a compressed air audit save?

A compressed air audit can typically identify opportunities to reduce energy consumption by 25% to 50%, depending on system condition and existing inefficiencies. Many businesses throughout Pennsylvania and Eastern Ohio achieve substantial savings through leak reduction, optimized pressure settings, improved controls, and better alignment between compressed air supply and demand.

How long does a compressed air audit take?

A compressed air audit timeline depends on the level of analysis. A Level 1 walkthrough evaluation can typically be completed in one day. A Level 2 system assessment usually takes 2–5 days, while a Level 3 comprehensive system audit may require 7-14 days to allow for detailed data logging and analysis of system performance over time.

What is included in a compressed air audit?

A compressed air audit includes a comprehensive evaluation of your system’s supply and demand, including compressors, air distribution, storage, and end use. Depending on the audit level, it may also include leak detection, pressure and flow measurement, data logging, system modeling, and a detailed report with recommendations to improve efficiency, reliability, and performance.