How to reduce operating costs with a compressor audit
February 23, 2026
Energy consumption accounts for up to 70% of the lifecycle cost of a compressed air installation. With the increase and the general uncertainty about energy prices it’s better to lower consumption as soon as possible.
An important question these days is how can we reduce the environmental impact of our company and lower operating costs? Nobody still needs to be convinced that we need to save energy and many companies have clear targets to reduce their energy consumption. In this article we will explain to you how to reduce the operating costs. Is it time to buy a more modern compressor? Or to replace the piping system? It all starts with an air compressor audit.
Every compressed air installation can be improved!
In most compressed air installations, there are many possibilities to save energy and very often they are unnoticed.
- Leakages: Compressed air installation of more than 5 years old has on average 20% of air leakages.
- Unloaded hours: Air compressors running unloaded consume on average 25% of their total power.
- Pressure band: Reduction of 1 bar net pressure results in 7% energy savings.
- Latest technology:Motor exchange can bring you up to 2% additional energy savings.
- Energy recovery:Use the heat of your air compressor to generate hot water. Compressors running at full load (24/7) will give you on average 80% of energy savings.
The most proactive and efficient way to minimize operational costs is conducting a compressor room audit like AIRScan.
Conducting a compressor audit: AIRScan
AIRScan is one of our tailor-made solutions which is fully consistent with your operating budget and can range from a basic to a full compressor inspection. The advantage of AIRScan is that there is no need to interrupt the production because the audit runs while the compressors are operational. Atlas Copco’s energy consultants determine an acceptable operating balance to satisfy production needs and minimize operational running costs.
The logged information is evaluated via our in-house audit software, which can simulate various configurations of compressed air installation. The received information is interpreted and presented in a detailed compiled report that includes:
- Cost & return analysis
- Measurements insight
- Optimization recommendations
An AIRScan report provides a clear summary for decision-makers, as well as an in-depth evaluation of problems and solutions for technical people. This allows us to provide realistic projections on potential energy savings, as well as environmental benefits.
What after the air compressor audit?
Once the audit is complete, our engineers walk you through:
- The key findings
- Prioritized improvements
- Expected cost savings
- Implementation timelines
This ensures that the recommended changes are not only clear, but also easy to execute and aligned with your operational goals.
Maximizing long-term cost savings
A standard maintenance schedule keeps your compressor running with only the essential upkeep, but it often leaves hidden issues unnoticed until they become expensive problems. Preventive maintenance, however, is a proven way to cut operational costs. By routinely inspecting and servicing your equipment, you can detect and resolve small issues early, avoiding major repairs, costly part replacements, and unplanned downtime. This proactive approach also keeps your compressor operating at maximum efficiency, reducing energy consumption and lowering overall running costs throughout its lifetime.
Can I reduce operating costs without stopping production?
AIRScan gives you precise data and actionable improvements to save costs—without ever stopping your production. We install advanced measuring equipment throughout your compressed air system and monitor performance from the compressor room to the point of use, ensuring a complete analysis with zero downtime.
How much can I save on operating costs with a compressed air audit?
Compressed air systems can consume up to 40% of a factory’s electricity bill. You can reduce this energy consumption by up to 30% by optimizing your system’s efficiency. Atlas Copco's unique compressor audit software simulates various configurations of your compressed air installation. This allows us to provide realistic projections on potential energy savings.
What does an AIRScan compressed air audit measure?
- Energy Audit: Measures key parameters—energy use, flow rates, and pressure—to assess system performance, followed by simulations of different system configurations.
- Air Quality Analysis: Checks compressed air purity and provides recommendations based on your required quality standards.
- Leak Detection: Uses an advanced acoustic camera that identifies up to 40% more leaks and works twice as fast as traditional methods.
- Vibration Analysis: Monitors rotating components (element, gearboxes, drive train) to detect issues early and prevent unexpected failures.
Why is an audit the most cost‑effective first step?
Before investing in new piping or a new compressor, you first need clarity on where losses occur. That’s why everything starts with a compressed air audit.
