Compressed Air Downtime Cost Calculator
- Sullair dealer since 1984
- Serving industry since 1978
- No form fill, nothing gated
What this calculator tells you
When the air system goes down, production goes with it. Put a number on what an unplanned outage actually costs your plant.
Your Plant
Results
Cost per downtime event:
$0
Annual exposure: $0 (2 event(s) per year)
A Total Care or AirCare Plus preventive maintenance plan typically costs a small fraction of one downtime event. Prevent problems. Protect production. Power performance.
How this is calculated
- Cost per event = (production value per hour + idled employees x loaded labor rate) x event hours + restart and scrap cost.
- Annual exposure = cost per event x unplanned events per year.
- Loaded labor rate means wages plus benefits and payroll costs, which is what idle time actually costs you.
Estimates only. Actual results depend on your equipment and operating conditions. Call 800.825.3222 for exact sizing.
Common questions
How much does compressed air downtime cost?
Cost per event = (production value per hour + idled employees x loaded labor rate) x hours of downtime, plus restart and scrap costs. A plant producing 5,000 dollars per hour with 10 idled workers at 35 dollars per hour, down for 6 hours with 1,000 dollars of restart cost, loses about 33,000 dollars in a single event. When the air system stops, most production stops with it.
How often do air compressors fail without preventive maintenance?
Plants running compressors without a preventive maintenance program commonly see one to three unplanned outages per year from causes like overheating, failed separators, clogged coolers, and electrical faults. Most of these failures give early warning signs that scheduled service catches before they take down production.
Is a compressor preventive maintenance plan worth the cost?
A preventive maintenance plan typically costs a small fraction of a single downtime event. Comparing an annual PM cost against the annual downtime exposure it prevents, the plan usually pays for itself if it avoids even a few hours of unplanned outage per year, before counting the energy savings from a well maintained machine.
Want a tech to verify these numbers at your facility?
Request received. If you need someone now, call 800.825.3222.
Please fill in all required fields (name, company, email, phone, preferred contact method, ZIP, and city), or call 800.825.3222.
These are planning numbers. Exact quotes come from your equipment list.
Rates, schedules, and equipment condition all move these totals. A Brabazon engineer verifies the numbers at your facility before anything is quoted.