Why It Matters:
Compressed air is one of the most expensive utilities in industrial facilities. Yet, many plants unknowingly lose 20–30% of their total compressed air to leaks—costing lakhs annually in wasted electricity.
At Navkar Engineering, we’ve audited systems where fixing air leaks alone reduced power bills by 15–25%.
Compressed air is one of the most expensive utilities in industrial facilities. Yet, many plants unknowingly lose 20–30% of their total compressed air to leaks—costing lakhs annually in wasted electricity.
At Navkar Engineering, we’ve audited systems where fixing air leaks alone reduced power bills by 15–25%.
The Hidden Cost of Air Leaks
Let’s break it down:
1/8-inch (3mm) hole at 7 bar can waste over ₹1,00,000/year in electricity.
Even tiny leaks (1 mm) can cost thousands per month.
Leaks cause compressors to run longer, increasing:
Energy usage
Maintenance frequency
Wear & tear
Unplanned downtime
Bottom line: Air leaks = Money leaks.
Let’s break it down:
1/8-inch (3mm) hole at 7 bar can waste over ₹1,00,000/year in electricity.
Even tiny leaks (1 mm) can cost thousands per month.
Leaks cause compressors to run longer, increasing:
Energy usage
Maintenance frequency
Wear & tear
Unplanned downtime
Bottom line: Air leaks = Money leaks.
Common Leak Points
Air leaks often go unnoticed because they’re silent and invisible. But here’s where you should look:
Pipe joints & elbows
Quick connect couplings
FRLs (filter-regulator-lubricator units)
Auto drain valves
Hoses and flexible lines
Open or unisolated tools not in use
Flange gaskets and thread connections
Air leaks often go unnoticed because they’re silent and invisible. But here’s where you should look:
Pipe joints & elbows
Quick connect couplings
FRLs (filter-regulator-lubricator units)
Auto drain valves
Hoses and flexible lines
Open or unisolated tools not in use
Flange gaskets and thread connections
How to Detect Leaks
1. Ultrasonic Leak Detectors
The most accurate and reliable method. These devices “listen” for high-frequency sounds of leaking air and guide you to the exact spot.
The most accurate and reliable method. These devices “listen” for high-frequency sounds of leaking air and guide you to the exact spot.
2. Soapy Water Spray
Spray joints and suspect areas—bubbles indicate a leak. Cost-effective, but time-consuming for large systems.
Spray joints and suspect areas—bubbles indicate a leak. Cost-effective, but time-consuming for large systems.
3. Pressure Drop Observation
Monitor pressure gauges when machines are idle. Rapid drop = leaks.
Monitor pressure gauges when machines are idle. Rapid drop = leaks.
4. Professional Leak Audit
We recommend scheduling quarterly leak detection audits—especially in older installations or after major expansions.
We recommend scheduling quarterly leak detection audits—especially in older installations or after major expansions.