Compressed Air Leaks: The Hidden Profit Drain

Compressed Air Leaks: The Hidden Profit Drain

Small Leaks. Big Impact. Real Money Lost

Compressed air leaks can waste 20% to 30% of your compressor output. That means you’re paying to make air that never reaches your tools, machines, or production.

One 1/4″ Leak Can Cost Over $15,000 Per Year!

The True Cost of a 1/4″ Leak

Example: 1/4″ hole at 100 PSIG

• Air Loss = 100 CFM
• Power Required = 18 kW
• Electricity Rate $0.10 per kW
• Operation 24/7/365 (8,760 hrs/yr)

Annual Cost of This One Leak

$15,768 Per Year

That’s just in electricity. Does not include added wear, maintenance, or lost productivity.

Why Are Leaks So Expensive

• Higher energy bills
• Longer compressor run time
• Increased maintenance costs
• Reduced equipment life
• Pressure instability
• Lost production performance

Common Leak Sources

• Couplings & quick connects
• Hoses & hose reels
• Pipe joints & fittings
• Filters, regulators & lubricators
• Drain valves & condensate drains
• Valves, manifolds & cylinders

Find It

Inspect regularly. Use ultrasonic leak detection.

Tag It

Document every leak. Prioritize the largest first.

Fix It

Repair correctly. Verify the leak is gone.

Track It

Monitor results. Measure savings and improvements.

Prevent It

Maintain your system. Train your team. Stop leaks early.

The Sullivan-Palatek Advantage

Sullivan-Palatek compressors are built for reliable, long-lasting performance, but even the best compressor can’t overcome wasted air. A poorly maintained compressed air system can increase energy costs, reduce pressure stability, accelerate equipment wear, and limit the performance of your compressor. Before investing in additional compressor capacity, ask yourself: Are you truly short on air, or are you simply losing it through leaks?

A leak detection and repair program is one of the fastest and most cost-effective ways to improve system efficiency, often freeing up capacity, lowering operating costs, and increasing production reliability without adding another compressor. In fact, a single 1/4-inch air leak can cost more than $15,000 per year in wasted energy when operating continuously.

Don’t Let Profit Leak Out of Your Plant.

Partner with Sullivan-Palatek to build a stronger, more reliable, and more efficent compressed air system.