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The Hidden Cost of Compressed Air in Industrial Settings

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Compressed air systems are integral to various industrial processes, yet A2EP’s research indicates that they can consume approximately 16% of a typical manufacturing site’s electricity. Alarmingly, 80% to 90% of this energy is often wasted due to factors like leaks, overproduction, and outdated equipment.

On May 20, 2025, the Australian Alliance for Energy Productivity (A2EP) hosted a pivotal webinar titled “Unlocking Compressed Air Efficiency for Serious Energy SavingsElectricity or gas savings or both..” This session illuminated the substantial energy-saving potential within compressed air systems, which, despite their ubiquity in manufacturing, often operate with significant inefficiencies.

listen to the full webinar discussion here

Insights from Industry Experts

The webinar featured insights from leading professionals:

A Call to Action for Energy Managers

This webinar serves as a valuable resource for energy managers, engineers, and industry professionals aiming to enhance operational efficiency, reduce costs, and lower emissions. By addressing the often-overlooked inefficiencies in compressed air systems. Want to increase your industrial energy savings? Contact Craig Morgan at Northmore Gordon today!

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How much of a typical manufacturing site's electricity can compressed air systems consume, according to A2EP's research?

According to A2EP's research cited in the article, compressed air systems can consume approximately 16% of a typical manufacturing site's electricity.

What percentage of energy used in compressed air systems is often wasted, and why?

The article states that 80% to 90% of the energy used in compressed air systems is often wasted due to factors like leaks, overproduction, and outdated equipment.

What webinar did the Australian Alliance for Energy Productivity (A2EP) host, and when?

On May 20, 2025, A2EP hosted a webinar titled "Unlocking Compressed Air Efficiency for Serious Energy Savings," which highlighted the substantial energy-saving potential within compressed air systems despite their common inefficiencies in manufacturing.

Who were the industry experts featured in the A2EP compressed air webinar, and what did they discuss?

The webinar featured three experts: Satinder Sahni, Group Senior Manager – Utilities at Asahi Beverages, who shared strategies for reducing compressed air costs by minimizing air consumption; Murray Nottle, an air systems engineer from the Carnot Group, who discussed using 'Power vs Flow' curves as a diagnostic tool to identify and prioritize efficiency improvements; and Craig Morgan, Group Sales Director at Northmore Gordon, who presented findings from a measurement-based survey of 30 compressed air systems.

What did Craig Morgan present at the A2EP webinar?

Craig Morgan, Group Sales Director at Northmore Gordon, presented findings from a measurement-based survey of 30 compressed air systems, revealing surprising inefficiencies and offering guidance on assessing system performance.

How did Asahi Beverages reduce compressed air costs?

Satinder Sahni, Group Senior Manager – Utilities at Asahi Beverages, shared strategies on how Asahi significantly reduced compressed air costs by minimizing air consumption in their processes.

What tool did Murray Nottle discuss for diagnosing compressed air inefficiencies?

Murray Nottle, an air systems engineer from the Carnot Group, discussed the utilization of 'Power vs Flow' curves as a diagnostic tool to identify and prioritize areas for efficiency improvements in compressed air systems.

Who should be contacted to increase industrial energy savings related to compressed air systems, according to the article?

The article encourages readers to contact Craig Morgan at Northmore Gordon (via email at c.morgan@northmoregordon.com) to increase industrial energy savings.

Where can the full A2EP compressed air webinar discussion be viewed?

The full webinar discussion can be viewed via a linked YouTube video referenced in the article, titled to accompany the discussion "Unlocking Compressed Air Efficiency for Serious Energy Savings."

Why is leakage considered a major hidden cost in compressed air systems?

According to the knowledge-base context, leakage is a primary source of unexplained air-system load, with undetected leaks throughout distribution piping from the compressor to end-use points resulting in continuous energy waste. A leak survey is a critical investigation method used to identify and quantify these leaks, yet many facilities operate without ever conducting one.

What other factors besides leaks contribute to hidden costs in compressed air systems?

Per the knowledge-base context, hidden costs also stem from unnecessary demand (using compressed air for tasks that don't require it), idling (compressor equipment running without productive output), and pressure setting issues where compressors work harder than necessary if pressure isn't optimized based on actual critical user requirements.

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