Compressed Air Audits

Compressed Air Audits

Uncover hidden inefficiencies and unlock energy savings with a compressed air audit designed to improve compressed air efficiency across your entire system. Our expert system assessments include advanced air leak detection, pressure mapping, and usage analysis — delivering actionable insights that reduce energy costs, cut waste, and boost overall plant reliability.

What to Expect
Partnering with John Henry Foster (JHF) means expert guidance through every phase of improving your compressed air system. Our step-by-step approach is designed to increase compressed air efficiency, reduce downtime, and drive measurable energy savings, from the first compressed air consultation to long-term ROI tracking. 

 Initial Consultation 
We begin with a no-pressure, no-obligation compressed air consultation to evaluate your facility’s needs. This energy audit intake helps us understand your industrial air system usage, goals, and challenges so we can tailor our recommendations for maximum efficiency.

On-Site Compressed Air Audit 
Our certified specialists perform a detailed compressed air audit using data logging, flow analysis, and ultrasonic air leak detection. This real-time monitoring uncovers pressure drops, inappropriate uses, and inefficiencies in your system that impact performance and cost. 

Custom Efficiency Report 
Following the audit, you’ll receive a thorough compressed air system report that breaks down your current performance and highlights opportunities for energy savings. We also include actionable ROI analysis so you can prioritize upgrades that deliver the biggest impact. 

Implementation Support 
Whether you need full system upgrades or targeted improvements, our JHF team provides hands-on support. From leak remediation to compressed air system upgrades, we help you implement best practices for long-term compressed air optimization. 

Rebates & ROI Tracking 
Our experts help you take advantage of available energy rebates and utility incentive programs, ensuring you maximize your return. We also offer tools and support for ongoing compressed air ROI tracking, so you can monitor savings over time. 
Air Leak Detection & Remediation Services
Up to 30% of compressed air is lost through leaks, which leads to higher energy bills and decreased system performance. But not all leak fixes are created equal. Without the right strategy, incorrect repairs can cost more in wasted air, downtime, and unnecessary labor. That’s why JHF offers professional leak detection services using advanced ultrasonic leak testing to pinpoint issues precisely. Our certified team provides immediate air loss prevention and reliable repairs to help you maintain a more energy-efficient compressed air system, ensuring the job is done the right way, the first time. 

Ultrasonic Leak Detection Technology

Leak detection technicians use ultrasonic sensors to "listen" for high-frequency sounds produced by air escaping under pressure. These sounds are often inaudible to the human ear but can be pinpointed with handheld detectors. The turbulent, high-frequency sounds generated by leads are converted into an audible signal by ultrasonic detectors and displayed in strength levels on a screen. This allows technicians to detect leaks in noisy environments, from a distance, and to identify issues that aren’t visible or audible to other workers. 


Systematic Scanning

Technicians walk through your facility and scan all air lines, fittings, couplings, valves, hoses, and pneumatic components. Common leak points include:


  • Quick-connect fittings

  • Pipe joints and flanges

  • Solenoid valves

  • Worn hoses and seals

  • Drain traps and regulators


Leak Tagging & Documentation

Once a leak is detected, it’s tagged and recorded with details such as:

  • Location

  • Estimated leak size (CFM loss)

  • Cost impact

  • Recommended repair


This information is compiled into a leak report as part of a compressed air system audit, providing actionable data for repair and ROI tracking.


Remediation

Depending on the severity and system design, leaks can often be fixed immediately or scheduled for maintenance. Proper remediation ensures leaks stay fixed and energy savings are realized.

Demand Side Optimization
JHF helps you maximize efficiency where it matters most. With our compressed air demand analysis, you can improve performance and reduce waste. We evaluate your system’s point-of-use applications, identify unnecessary consumption, and provide pressure drop solutions that maintain output while lowering energy use. From air flow optimization to selecting energy-efficient air tools, our demand-side improvements help you get the most from your compressed air investment.

Air Leaks

Air leaks are one of the most common and costly sources of energy waste in compressed air systems. Even minor leaks from fittings, valves, or hoses can lead to significant losses over time, forcing compressors to run more frequently and for longer durations. Routine leak detection, tagging, and timely remediation are essential to maintaining system efficiency. Using ultrasonic leak detectors and implementing a structured leak management program can greatly reduce waste and improve overall system performance.

Inappropriate Uses of Compressed Air

Compressed air is often used for tasks it’s not suited for, such as cooling workstations, sweeping floors, or powering tools that could be run electrically. These inappropriate uses increase energy demand without adding value and reduce the capacity available for critical operations.

By replacing these uses with blowers, electric tools, or vacuum systems, facilities can reduce compressor load, lower energy costs, and extend equipment life. A comprehensive audit can help identify and eliminate these inefficiencies.

Pressure Drop

Excessive pressure drop occurs when air loses pressure as it moves through the system, often due to undersized or poorly laid-out piping, dirty filters, or excessive distances between the compressor and point of use. This drop forces compressors to work harder to maintain desired pressure levels, resulting in increased energy consumption and reduced system lifespan. Regular maintenance, proper piping design, and replacing clogged filters help minimize pressure drop and maintain efficient airflow throughout the system.

Point-of-Use Equipment

The tools and devices that use compressed air, like cylinders, actuators, and pneumatic tools, play a critical role in overall system efficiency. Inefficient or outdated equipment can consume more air than necessary, creating excess demand.

Optimizing point-of-use equipment involves evaluating tool performance, using air tools rated for efficiency, and ensuring proper flow regulation. Adding features like local regulators and shut-off valves helps reduce unnecessary air consumption and improves control. 

Flow Regulation & Control

Uncontrolled airflow can lead to over-pressurization, energy waste, and unnecessary wear on tools and systems. Installing pressure regulators, flow controllers, and automatic shut-off valves helps match airflow to actual demand, especially during idle periods or low production hours. These controls maintain consistent pressure at the point of use without overloading the entire system. With proper flow regulation, you can improve energy efficiency, extend equipment life, and avoid fluctuations that reduce process reliability.

Air Storage and Receiver Sizing

Properly sized receiver tanks play a vital role in stabilizing pressure and managing demand fluctuations in a compressed air system. Undersized or poorly placed air storage can lead to frequent compressor cycling, reduced system efficiency, and pressure instability at the point of use.

Assessing whether your primary and secondary receivers are correctly sized helps ensure sufficient buffering during peak demand and compressor transitions. A well-designed storage strategy improves system responsiveness, reduces energy use, and protects compressors from unnecessary wear.

Production Scheduling & Demand Events

Short bursts of high air demand, such as from machine startups or simultaneous tool use, can cause pressure drops and excessive compressor cycling, leading to energy waste and system strain. Identifying these events through air audits or monitoring tools allows for smarter system control.

Using demand valves, load/unload controls, or strategically placed air storage can help smooth out demand spikes. Aligning compressed air production with actual usage patterns and scheduling can significantly reduce peak loads and improve overall system efficiency. 

Condensate & Moisture Management

Moisture in compressed air systems can lead to corrosion, flow restrictions, equipment damage, and product contamination. Proper condensate management—including functioning dryers, filters, and automatic drains—is essential to maintaining air quality and system reliability.

Regularly inspecting and servicing point-of-use dryers, moisture separators, and drain valves ensures water is effectively removed before it can cause problems. A well-maintained moisture management system contributes to longer equipment life, improved productivity, and reduced maintenance costs.
Supply Side System Design & Upgrades
Upgrade your compressed air infrastructure with JHF’s expert compressed air system design services. We help you implement the right compressor upgrades, controls, and energy-efficient air dryers to match your application needs. With smarter compressed air controls and supply-side optimization, you can boost reliability while cutting energy costs across your facility.

Air Compressor Selection & Sizing
We right-size your air compressors to meet actual demand — avoiding the inefficiencies that come with oversizing or underperformance. Whether your application requires rotary screw, scroll, or variable speed drive (VSD) models, our experts guide you through the right compressor upgrades for your facility.

Air Dryer & Filtration System Upgrades
JHF ensures your system delivers clean, dry air with high-performance, energy-efficient air dryers — including refrigerated, desiccant, membrane, or heat-of-compression (HOC) models — paired with multi-stage filtration. These upgrades protect downstream equipment and help you comply with ISO 8573.1 air quality standards.

Air Receiver Tank Sizing & Placement
We assess and optimize your air receiver tanks to support system reliability and reduce compressor cycling. Proper sizing helps buffer demand spikes, stabilize pressure, and maximize the efficiency of your compressed air system.

Piping System Design
Our team designs efficient piping layouts that reduce pressure drop, minimize flow restrictions, and improve overall air delivery. Material selection and layout strategy — from loop systems to drops — are tailored to support consistent performance.

Controls & Automation Integration
Take command of your compressed air supply with advanced compressed air controls, such as master controllers and sequencing systems. These upgrades offer real-time response to fluctuating demand, driving supply-side optimization and reducing unnecessary energy use.

Heat Recovery Systems
Capture and repurpose waste heat from your compressors to preheat water or supplement building heat — a simple way to turn energy losses into savings while supporting sustainability goals.

Performance Monitoring & Analytics
JHF installs sensors, meters, and software to enable real-time system monitoring. You’ll gain visibility into usage trends, pressure stability, and efficiency metrics — helping you drive informed decisions and track your compressed air ROI over time.
Utility Incentives & Energy Rebates
Make your efficiency improvements work even harder with JHF’s support in securing compressed air rebates and utility incentives. We guide you through the process of applying for energy rebate programs, ensuring you benefit from available efficiency upgrades. Plus, we help you calculate and track your compressed air ROI, so you can see the financial impact of your investment.

Compressed Air System Audits
  • Rebate coverage: Partial or full reimbursement for professional compressed air audits.
  • Eligibility: Often requires pre-approval and must be conducted by a certified auditor or trade ally.
  • Purpose: To identify system inefficiencies like leaks, improper pressure settings, and inappropriate uses.

Leak Detection & Remediation
  • Rebate coverage: Rebates for documented leak repair based on estimated air savings (usually in CFM).
  • Conditions: Verified before-and-after measurements or leak log documentation may be required.
  • Example: $20–$50 per CFM of leak reduction.

Equipment Upgrades
  • Variable speed drive (VSD) compressors
  • Energy-efficient air dryers
  • Zero-loss condensate drains
  • Master controls or sequencing systems
  • Rebate type: Flat-rate or performance-based (e.g., dollars per kWh saved).
  • Typical incentive: Covers 20–50% of equipment costs, depending on energy savings and payback period.

Demand-Side Optimization
  • Flow control valves
  • Pressure regulators
  • High-efficiency air tools
  • Rebates are often tied to: Reduced system pressure or decreased total air consumption.

Performance Monitoring & Controls
  • Incentives for: Installing real-time monitoring systems or integrating automated control solutions.
  • Purpose: To maintain long-term energy savings and reduce overuse.

Custom Project Incentives
  • Some utilities offer custom energy incentives for large-scale projects based on total kWh or therms saved.
  • Requires documentation, engineering analysis, and pre/post verification.

Requirements to Qualify
  • Submit project applications before installation begins.
  • Use approved contractors or trade allies.
  • Provide system documentation, audits, or measurement and verification (M&V).
  • Complete final inspection or post-installation verification (in some cases).

Benefits
  • Reduced upfront project costs
  • Shortened payback period
  • Improved compressed air efficiency
  • Stronger ROI and ongoing energy savings