Compressed-air energy audit - measured, documented, actionable
A compressed air installation audit identifies energy losses, inefficient parts of the system and potential problems in the operation of the compressors and the whole installation. It is the first step towards real savings and greater reliability.
Modern Tech Group carries out audits in small workshops and large factories alike. Our aim is to optimise operating costs and keep the installation running without failures. When the audit is complete, we prepare a detailed report with modernisation recommendations and savings estimates.
We implement the report's recommendations with our own team - from control settings to mechanical work as part of our screw compressor service.
What the audit produces
- Detailed report with the measurement results
- Leak map with locations and estimated losses
- Analysis of the installation's energy costs
- Prioritised modernisation recommendations
- Estimated savings once the changes are implemented
- Consultation with an engineer to discuss the results
Request an audit proposal
Send site address, number of compressors on site and rated power of each. We prepare an individual quote after an initial phone call - with no obligation.
Email the audit desk - biuro@moderntechgroup.plCompressed-air audit - scope and deliverables
The audit covers every key element of the compressed air installation. We assess the load, duty cycles and energy efficiency of each compressor and measure pressure on the key sections of the network to find pressure drops and bottlenecks. We locate leaks with ultrasonic detectors, measure the actual power draw and calculate what your compressed air costs to produce. We also check how well the filters, separators and dryers perform against air quality standards, and verify the controller configuration, operating sequences and energy-saving algorithms.
The measurements usually take 1-3 working days, depending on the size of the compressor room. On the first day we take stock of the compressor room and connect the data loggers; on the following days we record the consumption profile over the production cycle and check the installation for leaks. We hand over the report with the results and recommendations within a few days of completing the measurements. For large plants with several compressor rooms, we agree the schedule individually - always without stopping production.
Leaks typically account for 20-30% of a plant's compressed air production and are the cheapest source of savings to remove. We locate them with an ultrasonic detector while the plant is running normally, mark them and convert them into an annual energy cost. The leak check covers the whole network - from the compressor outlet valve, through headers, branches and quick couplings, to tool connections and the pneumatic equipment on machines. We separately check the points that cause the most losses in practice: worn quick couplings, cracked spiral hoses, timer-controlled condensate drains and leaking cylinders.
Why a real audit outperforms a quick walk-through
Numbers instead of guesswork
The most common mistake when buying a new compressor is sizing it by eye - from the old machine's nameplate or by adding up the demand of every consumer. The first means buying a machine that is too small or repeating a ten-year-old mistake; the second means paying for power that never runs. An audit carried out before the purchase turns guesswork into numbers: the real consumption profile over a weekly cycle, peaks and troughs, the share of idle running and the minimum pressure at which production machines work properly.
Measurement record
A summary of every measurement taken: power draw of each compressor, loaded and idle running times, pressure in the compressor room and at the furthest consumers, temperature and dew point after the dryer, and pressure drops across the filters. For each item we state the measurement conditions and point, so the result can be repeated and compared later.
Leak list with the cost of each loss
A numbered list of leaks with location, estimated outflow and annual energy cost, ranked from the most expensive, so your maintenance team can fix them in order of cost.
Air consumption profile
A demand chart over the daily and weekly cycle: production shifts, stoppages, weekends and peaks at line start-up. The profile shows whether a variable speed drive or a larger air receiver pays off, how to set up a cascade of several machines and how much air the plant uses when nothing is being produced - which is usually pure loss.
Recommendations with estimated payback
Actions in three groups: to do immediately (leak sealing, pressure settings, condensate drain mode), to plan in the budget (dryer replacement, rebuilding a section of the network, variable speed drive) and to consider as an investment (new compressor, heat recovery). Each item shows the estimated annual saving and approximate payback period, so the order of work follows the numbers, not impressions.
FAQ - compressed-air audits
More from our compressed air services
Contact
Need an inspection, overhaul or rental? Fill out the form - we'll respond within 24 hours.
Send inquiry
Find us on the map
ul. Słowackiego 201 26-600 Radom Mazovian Voivodeship, Poland