Compressed Air Leaks: The Hidden Cost to Your Business
Every litre of compressed air that escapes through a leak has already cost your business money to produce. Your compressor has taken electrical energy and converted it into compressed air, and if that air escapes before reaching the machinery that needs it, that energy has effectively been wasted. As leaks increase, compressors need to run longer to maintain system pressure, which drives up electricity consumption, running hours, and wear on equipment, while reducing the overall efficiency of the whole system. That's why compressed air leak detection isn't simply about finding an annoying hissing sound. It's about improving the efficiency, reliability, and performance of your entire compressed air system.
At Airlinc Systems, we know there are many different reasons why compressed air leaks develop, and simply repairing the leak isn't always enough. It's important to understand why the leak occurred in the first place, so the underlying problem can be corrected.
Why Leaks Happen
Here's a run-through of the most common causes, grouped into five areas.
Installation and Parts
Poor installation is one of the biggest culprits, since even a new system can develop problems if fittings and pipework weren't installed correctly for the application and environment. Cheap or poor-quality components might save money upfront, but they create reliability problems down the track. Sometimes a perfectly good product is simply installed in the wrong place for the conditions it's exposed to. Incorrect seals or sealant, using the wrong type or the wrong amount, can let air escape from otherwise sound connections.
Age and Wear
Old joints and ageing systems deteriorate over time, sometimes with internal corrosion from water passing through, or seal damage from oil in the system. Cracked hoses are another common source, and a hose can look perfectly fine from a distance while still leaking from small cracks you can't easily see.
Environment
Pipework needs to suit where it actually lives, whether that's buried underground, exposed outdoors to heat and rain, sitting in direct sunlight and UV exposure, or suspended overhead where weight and proper support become critical.
Mechanical Stress and Movement
Vibration from compressors and machinery can loosen fittings over time. Connections directly to machines flex and move with the equipment, placing extra stress on fittings. And pulling on a hose that doesn't quite reach the work area transfers force back into the fitting and pipework, loosening or damaging it over time. The better fix is installing an outlet in the right position in the first place.
Damage and System Changes
Pipework, drops, and hoses can be accidentally struck by forklifts, machinery, or people, weakening a fitting even if it doesn't fail immediately. And poorly planned extensions to older systems, where someone taps in the wrong pipework or incompatible materials, can create leaks at the new connection point.
We'll cover flexible tubing selection for different industries and environments in a separate article.
Don't Just Fix the Leak — Find Out Why It Happened
Finding a leak is only the first part of the job. If a fitting is leaking because the wrong product was installed, simply tightening or replacing it may not solve the underlying problem. The same applies to vibration, corrosion, incorrect pipework, poor support, unsuitable seals, environmental exposure, or incorrect flexible tubing. A proper assessment looks at why the leak developed and what needs to change to stop it happening again.
Spotting a Leak Early
Listen for hissing near fittings and joints during quieter periods. For a more thorough and accurate survey, especially in noisy factory environments where leaks are hard to hear, ultrasonic leak detection picks up what the ear misses.
How Airlinc Systems Can Help
At Airlinc Systems, we provide compressed air leak detection, repairs, servicing, pipework installation, system modifications, and upgrades for industrial and commercial compressed air systems. Whether you have one troublesome leak, an ageing installation, or a large factory network with multiple leaks, we can assess the system, identify the problems, and recommend practical solutions.
Contact Airlinc Systems today to arrange a leak detection survey or a complete system assessment for your compressed air network.
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