Air Compressor Audit: A Step Towards Enhanced Productivity

By Heath Brabazon, President | Published: November 2024

For facilities relying on industrial air compressors, maximizing productivity and minimizing downtime is paramount. Brabazon stands at the forefront of this mission, championing the cause of a regularly scheduled air compressor audit to ensure optimal performance and longevity of these pivotal machines. Keep reading to learn why these audits are so important, what they tend to include, and how Brabazon can support you in this endeavor.

The Imperative

The Imperative of Regular Air Compressor Audits

Industrial air compressors, though robust, are not immune to wear and tear. Regular monitoring and maintenance of these systems are essential to detect and preempt potential issues. By proactively assessing how these compressors and their ancillary systems operate, you can circumvent potential problems, ensuring uninterrupted operations. By sidelining such challenges, you steer clear of potential inventory and profit losses that can arise from unforeseen downtime.

Delving Deep: What Does an Air Compressor Audit Entail?

An air compressor audit is more than a cursory glance at the system. It's a meticulous evaluation prioritizing:

Air Demands and Supply: Assessing if the compressor meets the air demand of the facility efficiently.
Detection and Address of Leaks: Leaks can be significant culprits behind efficiency drops.
Pressurization Levels: Ensuring ideal air compression levels in the system to meet demands without overexertion.
Bag Piping Assessment: Checking the state of the bag piping to spot any areas of concern.

Addressing these components may necessitate the replacement of filters, separators, and occasionally even the piping, ensuring they match the system's size and capacity requirements. Further, tweaks in system pressure might be required, and any detected leaks need swift redressal.

Brabazon’s Unparalleled Air Compressor Services

At Brabazon, we've honed our craft over the years, bringing together a team of seasoned air compressor technicians familiar with major industry manufacturers. Our dedication goes beyond mere repairs; we offer an encompassing air compressor maintenance plan – the AirCare Plus™ Planned Maintenance with Remote Monitoring. Subscribers to this plan can anticipate regular tune-ups, system monitoring, and a thorough 100-point inspection with each visit. Brabazon's technicians, annually certified with the latest industry updates, not only address immediate needs but are also highly skilled and professionally trained. Brabazon even has a technician training center led by an instructor with more than 25 years of compressor industry experience. With facilities strategically located across various regions, from Green Bay to Chicago and St. Louis, we're positioned to meet your service needs promptly. The AirCare Plus™ package is a testament to our commitment to excellence. This comprehensive plan ensures your compressor remains in prime condition, minimizing operating costs. With options like 24/7 Remote Monitoring, we keep a vigilant eye on your system, ensuring it operates efficiently. Monthly reports that detail pressure levels, flow rates, and energy costs help operators fine-tune their systems, leading to cost savings and enhanced productivity.

What Happens During a Brabazon Compressed Air Audit?

A Brabazon compressed air audit is a systematic, data-driven evaluation of your entire compressed air system — from the compressor room to the point of use. Here's what our certified technicians assess during a typical audit:

Flow and demand profiling — We measure actual compressed air demand across different production shifts to identify over-pressure and waste periods
Leak detection survey — Using ultrasonic detection equipment, we locate and quantify leaks throughout your distribution piping. The average unaudited facility loses 20–30% of its compressed air to leaks
Pressure drop analysis — Excessive pressure drop across piping, filters, or dryers signals undersized components or excessive demand that can strain your compressor
Energy cost assessment — We calculate the true cost per unit of compressed air produced and identify opportunities to reduce energy consumption through pressure optimization, VSD upgrades, or system right-sizing
Equipment condition review — We assess the current state of your compressors, dryers, filters, and controls, flagging items approaching end-of-life or operating outside of optimal parameters

Why Midwest Manufacturers Choose Brabazon for Compressed Air Audits

Brabazon has performed hundreds of compressed air audits across Wisconsin, Illinois, Minnesota, Indiana, and Missouri. Our technicians hold annual certifications from major compressor manufacturers including Sullair, and our instructor-led training center ensures our team stays current with evolving equipment and efficiency standards. When you schedule a compressed air audit with Brabazon, you get a comprehensive written report with prioritized action items — not a sales pitch for unnecessary equipment.

Taking the Next Step Towards Optimal Productivity

Compressed Air Audit FAQ

How long does a compressed air audit take?
Most facility audits can be completed in a single day, though larger facilities with complex multi-zone systems may require 2–3 days to fully profile demand patterns across all production shifts. Brabazon provides the completed report within a week of the audit date.

How much can I save with a compressed air audit?
Savings vary widely, but many facilities recover their audit investment within 6–12 months through reduced energy costs, fewer unexpected repairs, and longer equipment life. Facilities with significant leak losses often see 15–25% reductions in compressed air energy costs after implementing audit recommendations.

Do I need to shut down production for the audit?
No. Brabazon performs audits around your production schedule. In fact, the most accurate demand profiling occurs during normal operating conditions. Our technicians are trained to work safely around active production equipment.

Does Brabazon offer audits in my area?
Yes. Brabazon serves facilities throughout Wisconsin (Green Bay, Milwaukee, Madison, Wausau, Eau Claire), Illinois (Chicago, Rockford, Decatur, Marion), Minnesota (Minneapolis, Duluth), Indiana (Michigan City), and Missouri (St. Louis, Jefferson City). Contact your nearest Brabazon location to schedule your audit.