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.