Its reliability, ease of use, and adaptability make it the fourth most widely used energy source in industry, following electricity, natural gas, and water. However, producing compressed air is not as efficient as it may seem. In fact, it’s one of the most energy-intensive resources in industrial settings, consuming a significant portion of a facility’s electricity.
The true cost of compressed air
While most industries recognize the value of compressed air, few fully grasp its hidden costs. On average, compressed air accounts for 13% of industrial electricity consumption in countries like France, with similar figures worldwide. But what’s surprising is that more than 90% of the electrical energy used in air compression is lost—primarily in the form of heat—leaving only 8-10% of the energy to perform useful mechanical work. The rest is simply wasted.
For facilities that run compressors 6,000 to 8,000 hours annually, energy consumption can constitute up to 80% of the total cost of compressed air production over five years. When one considers that a cubic meter of compressed air at 7 bar requires 200 Wh to produce, it’s easy to see why inefficiencies like leaks become so expensive.
The hidden drain
One of the biggest contributors to this inefficiency is the presence of leaks within the compressed air system. While leaks don’t typically pose safety risks or directly disrupt production, they are a major source of energy waste. On average, 30-40% of compressed air production is lost through leaks. In some cases, this number can be even higher. Globally, the average leakage rate is estimated at 34%. This means that one out of every three compressors in a facility could be working just to supply the air lost through leaks—an unacceptable waste of energy and money.
Because leaks are odorless, invisible, and often inaudible in noisy industrial environments, they frequently go unnoticed. But the financial impact of these leaks is significant.
