The cost of air leakage: A hidden drain on manufacturers' resources

12 November, 2024

Air leakage within manufacturing environments is prevalent yet frequently neglected. When air escapes from compressed air systems, it reduces efficiency and increases energy consumption, leading to higher energy bills, increased maintenance costs, and a reduced lifespan for machinery. Furthermore, the cumulative impact of undetected leaks drains resources that could be better spent on enhancing productivity.

Rubix's research reveals that air leaks represent one of the most significant drains on energy efficiency. Peacock emphasises that by proactively addressing air leakage through regular maintenance, continuous monitoring, and improved sealing practices, businesses can realise substantial cost savings, boost operational efficiency, and enhance their environmental performance.

Quantifying air leaks

Rubix has conducted research on the effects of air leakage on manufacturing revenue and operational costs. According to its findings, compressors account for approximately 30% of a manufacturing site’s total energy expenses, a significant figure given that many facilities rely on multiple compressors to power their production lines. Alarmingly, up to 30% of compressed air can be lost to leakage and misuse at any given facility, a loss that substantially affects total cost of ownership calculations.

Impacts of air leakage

Energy costs constitute a major portion of overall overheads, and these can be considerable. A report from the Department for Energy Security and Net Zero indicates that energy bills account for an average of 4% of overheads in the UK manufacturing sector. In a highly competitive industry characterised by tight margins, eliminating air leaks could significantly enhance profitability.

Peacock also notes the environmental implications of air leakage. Despite ongoing investments in renewable energy across Europe, the electricity consumed still carries a carbon footprint. Recent data from the Office for National Statistics shows that industry accounts for 14% of total UK emissions.

In addition to financial and environmental impacts, the safety risks associated with air leaks must not be overlooked. In manufacturing environments, leaks can pose serious hazards, potentially damaging equipment or injuring personnel. Operationally, air leaks can result in drops in system pressure, hindering the performance of air tools and production lines. This inefficiency can lead to increased maintenance costs for machinery, tools, and compressors, and may even shorten their lifespan. Some manufacturers might find themselves operating additional compressors or running at higher pressures than necessary to compensate for lost air.

Addressing air leakage

Identifying an issue is only the first step; quantifying it is crucial for implementing effective solutions. Rubix offers specialist air leak surveys, employing expert engineers equipped with advanced technology to conduct thorough audits that provide detailed insights into leaks, energy loss, costs, and CO₂ emissions. Rubix prides itself on a transparent approach to diagnosing and resolving air leakage issues. Before starting a survey, a clear scope is agreed upon, ensuring full transparency regarding costs, which can vary based on site size, the number of compressors, and the number of compressed air systems in use.

Audits are typically conducted by at least one engineer, with charges based on a per-engineer, per-day rate. Given that air leaks can lead to substantial financial losses, many businesses find they recover the survey costs within the first month after implementing necessary repairs. The findings from these surveys are documented on a dedicated platform, allowing engineers to present results on-site while providing centralised reporting across all locations. The audit report details each leak, including images and information on annual energy loss, costs, and CO₂ impact. Recommendations for required repairs and parts are also included. Should businesses choose to proceed with repairs, Rubix offers an estimated payback period for the associated costs. The necessary parts are sourced, and repairs are executed efficiently. Engineers can later return to the site to conduct follow-up audits, ensuring that the measures taken yield the expected benefits.

Many Rubix clients also opt to adopt condition monitoring solutions, collaborating closely with its reliability team to implement appropriate systems. This proactive approach ensures that issues are detected early, enabling swift interventions that minimise impacts on costs and environmental performance.

Additionally, Rubix provides REHAB workshops - developed personally to support customers in the effective management of compressed air systems. These training sessions focus on straightforward, cost-effective modifications to enhance performance, tailored to the specific needs of each customer. For instance, at Cereal Partners, it was demonstrated that a slight reduction in pressure did not negatively impact performance, but rather resulted in significant cost savings by reducing energy consumption and wear on machine components. A 1-bar reduction in pressure can lead to energy savings of up to 10%, showcasing the effectiveness of simple adjustments that incur no additional costs.

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Case study: Magna Exteriors

Magna Exteriors, a manufacturer of lightweight structural components for the automotive industry, produces products such as exterior trim, fascias, and liftgates. The company recently identified air leaks in its operations and enlisted the help of Rubix to resolve this issue.

“One area that required immediate attention was air leakage,” remarked Paul Howard, the Energy Improvement Co-Ordinator at Magna Exteriors. “We could hear them hissing. While air is free to breathe, it is one of the most expensive forms of energy when it comes to compression and pressurisation.”

To tackle this challenge, expert engineers from Rubix conducted a comprehensive leak detection audit of Magna Exteriors’ compressed air systems. Utilising advanced ultrasonic technology, they analysed the machinery and provided a detailed photographic report highlighting any identified leakages. This report not only pinpointed the location and size of each leak but also outlined the associated costs.

Equipped with this invaluable report, Magna’s maintenance team had a clear roadmap to address the leaks effectively. Additionally, Rubix recommended the installation of low-cost flow meters to monitor and measure air rates, ensuring ongoing, autonomous, and preventative maintenance.

“They produced an exceptional, detailed report,” Paul continued. “It included photographs, descriptions of the size and nature of each leak, along with the financial implications. Furthermore, the report contained a list of the specific parts needed to rectify each issue, complete with costings.”

Following the recommendations, Magna’s technicians used these reports to systematically address each leak, signing off on their completion as they progressed. Six months later, they repeated the audit and have continued to do so every six months since, enabling them to track and verify the success of this proactive approach.

Ultimately, the audit led to a reduction in Magna Exteriors' energy consumption, with savings of up to one third for their compressors. By eliminating leaks, the company found they no longer needed three compressors in constant operation; they can now efficiently meet all operational demands with just two full-time compressors and a backup.

In addition to this, Magna Exteriors has realised significant savings in maintenance costs for their compressors. Over the three years since Rubix conducted its survey and subsequent remedial work, the company has saved more than £130,000.

“It has genuinely enhanced our energy efficiency,” Paul noted. “Moreover, it was a very cost-effective service that came with a refund guarantee if we didn’t achieve equivalent energy savings; needless to say, we exceeded those savings effortlessly.”

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For further information please visit  https://solution.rubix.com

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