In practice, compressed air leaks generate continuous losses. That is why during the audit we first locate the leaks and then convert them into specific values: l/min, m³/year, kWh/year, cost/year, and CO₂/year. This provides the maintenance department with decision-ready data, not a generic statement that “there are leaks.”
Importantly, the report ranks leaks by repair priority and includes photo documentation, allowing you to plan repairs in stages while monitoring the results after each leak is eliminated.
Simply identifying the location of an air loss is only the first step, because the maintenance team also needs clear answers to two key questions: how much does it cost and what should be fixed first. That is why the audit combines leak detection with loss calculation and repair prioritization.
If you additionally need support in selecting installation components, proceed to the repairs and parts section. Calculation tools are available in the Knowledge Center – Compressed Air Calculators.
At the beginning, we collect the parameters required for calculations (e.g. operating hours, energy cost, compressor room assumptions), ensuring that the report makes financial sense, not only technical sense.
We detect leak points within the compressed air system and at end users. Each leak is then documented, because fast and accurate on-site identification is critical during subsequent repairs.
For each leak point, we calculate the loss values and assign a repair priority, allowing the maintenance team to start with the largest air losses first.
Finally, we prepare a report that is ready for implementation. Additionally, if repairs are planned in stages, leak status and results can be easily tracked after each repair.
The report serves both as a task list and a control tool. You first select the highest-priority repairs and then verify whether the losses have been reduced. In addition, it becomes much easier to justify purchases and system upgrades, because you present solid data supported by photos.
In practice, leaks tend to recur in similar locations, but their cost can differ significantly. That is why the audit does not assume a predefined “culprit” – it measures and organizes the results.
After the audit, the same areas usually reappear: connections, pipes, accessories at consumption points, and installation components. That is why the report organizes repairs by priority, allowing you to start with the largest losses.
If you carry out repairs in-house, you can select the required installation components in the store. The most commonly needed items are pneumatic fittings, pneumatic pipes and hoses, and hose clamps and brackets. If the issue relates to air quality, components for compressed air treatment (FRL) may also be required.
If you prefer to hand over the execution, proceed to leak repair and service. If the leaks concern end users or actuators, see also pneumatic component repair and refurbishment.
Describe the scope of your compressed air system and the components you want to include in the measurements. You can also indicate whether you are interested only in leak location, or in a detailed energy loss analysis with defined repair priorities. Based on this information, we will prepare an audit scope tailored to the actual needs of your plant.
If possible, please provide information on the number of production shifts and the approximate operating time of the system. These data allow for a more accurate estimation of potential savings and the real cost of compressed air losses.
A compressed air leak generates an ultrasonic signal. This makes it possible to locate leaks even in large systems and in demanding production environments. At the same time, the selection of appropriate measurement accessories helps narrow down the direction and quickly identify the exact leak point.
The kit includes all equipment required for on-site work. This ensures the audit is repeatable and the documentation is complete. At the same time, proper preparation of the measurement setup minimizes the risk of missing leaks.
The audit focuses on locating leaks and converting losses into units that are meaningful for the plant. First, leaks are identified and documented, then they are converted into l/min, m³/year, kWh/year, cost/year, and CO₂/year. As a result, you receive a clear action list rather than a vague statement that “leaks are present.”
l/min indicates the instantaneous leak rate, while m³/year shows how this loss accumulates over a year based on the assumed operating time. In practice, m³/year makes it easier to compare leaks and set repair priorities.
kWh/year results from the adopted method of converting compressed air losses into energy consumption. The annual cost then depends on the energy price and the operating time of the system. That is why the input data are agreed in advance, so the report reflects your actual plant conditions.
Yes. Photo documentation and location descriptions are practical elements, as they allow you to return to the exact point without having to search again. Photos also make it easier to assign repairs and verify completed work.
Priorities are based on the level of losses (e.g. cost/year) and technical conditions. This allows the maintenance team to eliminate the leaks with the greatest impact first, and then address smaller ones.
In most cases, yes, but this depends on access to the system and safety requirements. If there are difficult or noisy areas, it is advisable to define measurement windows. This makes the measurements safer and more repeatable.
Typically, the operating time (e.g. hours per year) and the method of energy cost allocation are required. If the plant uses specific assumptions for the compressor room, these are applied in the report. This ensures that results are comparable over time and between departments.
Yes. The report functions as a task list that can be revisited. In practice, a verification measurement is performed after the repair, and the status is then updated. This way, you know which actions actually reduced losses.
Typically, fittings, threaded connections, quick couplings, pipes in friction zones, and valves near machines. However, the distribution of losses can vary, which is why the audit is measurement-based rather than assumption-based.
The scope is defined at the start. We can focus on the distribution network, but it is often beneficial to include end users and consumption points as well, because leaks at machines can generate the highest annual costs.
Yes. If you carry out repairs in-house, typical components such as fittings, pipes, and hose accessories can be quickly selected in the store. If you prefer to outsource the work, you can proceed to CPP PREMA service offerings.
In that case, the total loss is key. A single small leak may seem insignificant, but dozens of similar points can generate a substantial annual cost. That is why the report organizes both major leaks and recurring minor ones.
Yes, because you receive quantified data and documentation. Modernization decisions are therefore data-driven projects rather than assumptions. The priorities in the report also indicate where modernization will deliver the greatest effect.
The report includes energy and cost conversions for leaks, making it a practical data source for analyses. At the same time, the calculation assumptions are transparent, allowing easy comparison with other methods used in the plant.
This depends on maintenance organization and parts availability. However, because the report includes prioritized tasks, you can start immediately with the largest losses and address the rest in stages.
Yes. If the report or observations indicate issues with air quality, compressed air treatment components can be helpful. The store includes an FRL category, while final selection depends on your system and operating conditions.
