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Compressed Air Flow Testing

Your plant's real air demand, leakage and cost, logged on a running system, not estimated.

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Service overview

What your air costs, and where it goes

Our engineers install calibrated flow meters, pressure sensors and power loggers on your running compressed air system, and record how much air your plant generates, where it goes and what each cubic metre costs. Flow is measured as standard volume flow, with the reference stated on every result, so figures compare across sites, shifts and years. Probes go in through ball valves, or through a hot-tapped connection while the line stays under pressure, and production carries on throughout.

A spot flow test logs one point, such as a compressor, a dryer or a production line, for hours to a few days to answer a specific question. A full flow audit logs the compressor room, the main branches and selected machines together over a production week, following ISO 11011:2013. Your report holds the logged graphs, each loss with its annual cost, prioritised recommendations and the baseline future savings are measured against.

  • Flow, pressure, powerLogged together on your running system
  • ISO 11011:2013Assessment framework for the audit
  • Annual costPut on every leak and loss
  • No shutdownProduction continues throughout

Benefits

The problems it solves

Compressed air is one of the most expensive utilities in a factory, and an electricity bill doesn't show where it goes. Here is what measurement uncovers.

  • An invisible cost

    The problem

    Your electricity bill shows total site use, not what the air system uses or wastes. Compressors run whether air feeds production or a leak.

    How it solves it

    Measured flow and power separate productive use from loss, and put a cost on every cubic metre.

  • Leaks that never stop

    The problem

    A single 3 mm hole at 7 bar g passes roughly 26 m³/h of free air, more than 13,000 kWh a year, and large plants have hundreds.

    How it solves it

    Leakage is reported in m³/min, kW and annual cost, and branch meters show which area leaks most.

  • Buying compressors you don't need

    The problem

    Low pressure at the far end is often leakage, a clogged filter or an undersized branch, not a lack of capacity.

    How it solves it

    A measured demand profile shows the real cause, and often that existing compressors can meet demand once losses are removed.

  • Setpoints creeping upward

    The problem

    Raising the setpoint to reach one starved machine makes every leak and open nozzle pass more air. Each extra bar adds about 7 % to compressor energy.

    How it solves it

    Pressure logged along the network finds the restriction, so it can be fixed and the setpoint lowered.

  • Energy management without data

    The problem

    ISO 50001 needs baselines and energy performance indicators, and savings claims need measured verification.

    How it solves it

    Logged baselines and post-project measurements support ISO 50001, ISO 50002 audits and ISO 50015 verification.

  • Guesswork sizing

    The problem

    Equipment chosen on guesses is either oversized, wasting energy at part load, or undersized, with pressure collapsing at peaks.

    How it solves it

    Compressors, dryers and receivers are specified against your actual peak, average and minimum flows.

Where it’s used

Wherever air is a big line on the power bill

Any plant running compressors can measure what they deliver. These are some of the heaviest users.

  • Robots welding a car body on an assembly line

    Automotive and components

    Assembly tools, paint shops and robot grippers drawing air in pulses, separated from leakage in large networks.

  • A row of yarn winding machines in a textile mill

    Textiles

    Air-jet looms using large continuous volumes, measured per loom to link air cost to fabric output.

  • Wine bottles moving along a bottling line

    Food and beverage

    PET bottle blowing, filling, packaging and conveying, metered per line to allocate cost and size systems.

  • Yellow tablets spilling from a medicine bottle

    Pharmaceuticals

    Tablet coating, capsule filling and packaging lines, with branch metering that supports GMP utility documentation.

  • Glowing glass bottles being formed on a production machine

    Glass, cement and steel

    Blow-off nozzles, bag filter cleaning, pneumatic conveying and burner controls, where excess pressure costs the most.

  • Electricity pylons and power lines at sunset

    Power plants

    Ash handling and instrument air systems, logged to verify compressor delivery and detect losses.

Also plastics and packaging, chemicals, refineries and fertiliser plants, electronics, paper and printing, energy managers and ESCOs, and compressor room planning for any industry.

Keep exploring

More from our range

Our other services, and equipment for every stage of your compressed air.

Why Settle for Mediocrity When You Can Partner with the Best?

We are more than just another industrial solutions provider. We’re a partner in your success. With decades of experience and a team of experts dedicated to providing comprehensive solutions from equipment to service and sourcing, we’re confident in our ability to help you optimize your performance and achieve your business goals.

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