Compressed air leaks waste 20–30% of output in a typical plant. Enter your system details to see how much those invisible leaks are costing you per year.
Typical plant: 20-30%
Average plant: 50-200
You're Losing
$12,000
per year in wasted electricity from air leaks
Air Wasted
100 CFM
of 400 CFM total output
Equivalent to
25 HP
compressor running for nothing
Energy Wasted
120,000 kWh
per year
CO2 Emissions
48 tons
from wasted energy per year
Program Cost
$9,000
Audit + 80 repairs
Annual Savings
$7,200
~60% of leak volume fixed
Payback Period
15 mo
typically 3-6 months
5-Year Net Savings
$27,000
| Leak Size | Air Lost (CFM) | Annual Cost |
|---|---|---|
| 1/16" diameter | 3.1 CFM | $372 |
| 1/8" diameter | 12.2 CFM | $1,464 |
| 3/16" diameter | 27.5 CFM | $3,300 |
| 1/4" diameter | 48.8 CFM | $5,856 |
| 3/8" diameter | 110 CFM | $13,200 |
| 1/2" diameter | 195 CFM | $23,400 |
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Compressed air is often called the "fourth utility" in manufacturing — and it's the most expensive per unit of energy delivered. A single 1/4-inch leak at 100 PSI wastes approximately 100 CFM and costs $8,000–$12,000 per year in electricity alone.
| Metric | Average Plant | Best Practice |
|---|---|---|
| Leak rate (% of output) | 20–30% | <10% |
| Cost per 1,000 CFM/year | $18,000–$25,000 | $12,000–$15,000 |
| Leak detection audit payback | 3–6 months | — |
| Annual savings from leak repair | $10K–$100K+ | — |
Ultrasonic leak detectors ($3,000–$15,000) can pinpoint leaks that are invisible and inaudible. Many plants hire third-party auditors ($2,000–$5,000 per audit) who typically find 50–200 leaks per facility. The ROI on leak detection programs is consistently among the highest of any maintenance investment.