In a typical industrial facility, as much as 20–30% of all compressed air produced escapes through leaks before it even reaches the machinery. This is literally the sound of money leaking away, clearly visible on the electricity bill.
Compressed air compressors account for approximately 3–12% of the electrical energy consumed by industry. Managing compressed air leaks is one of the easiest ways for a company to reduce energy costs. Compressed air is required in almost every production facility, yet few people consider what it actually costs. The cost of compressed air always varies due to changing factors in system settings and production. The annual cost caused by a single 2 mm diameter leak in a 7 bar system can amount to approximately €800–1,000 if the system is pressurized 24/7. A leak of this size is typical and small, but when numerous leaks accumulate in a large system, the true cost of leakage becomes apparent. In a single production facility, the annual cost of leaks can exceed €10,000.
Yes, it does and very often within the first year. A one-day survey costs approximately €1,500–2,000. If a survey is carried out in a factory for the first time, the leaks found almost invariably cost the same amount or more. It is a good idea to make leak detection surveys a part of regular maintenance, as they will pay for themselves many times over in the long run.
Yes, you can. The Audinos Elite Ex we use is such an easy-to-use device that you can also purchase one for your own company. We also provide guidance on using the device when you purchase it. Request a quote for the device using the form provided or contact our sales team.
Compressed air leaks can be detected and measured using equipment specifically designed for the purpose. We use the most advanced acoustic camera on the market, the Audinos Elite Ex. The device’s 138 MEMS microphones detect ultrasonic frequencies from 2 kHz to 100 kHz. Since the camera lens is surrounded by numerous microphones, the image can accurately indicate the exact point from which the sound is coming toward the camera. The camera detects sounds that humans cannot even hear, allowing every leak to be identified accurately while background noise from the factory does not interfere with the inspection.
The survey can detect leaks of air, gases, vacuum, and steam easily and accurately.
A typical compressed air leak survey costs approximately €1,500–2,000. We prepare a quotation based on the estimated size and location of your factory. We operate completely independently, and the survey does not cause any interruptions to production.
Once the compressed air leaks are repaired, the survey has almost invariably paid for itself the very first time. A leak survey is therefore a sensible measure not only from a financial perspective but also from an environmental standpoint. If you do not wish to order the survey as a service, you can also purchase the device for your own use. Let us determine the best solution for you together.
