Setting Compressed Air Efficiency Goals for the New Year

The beginning of the year is when many facilities set goals for safety, production, and cost control — but compressed air efficiency often gets overlooked. That’s a missed opportunity. Compressed air is one of the most expensive utilities in a facility, and even small improvements can produce meaningful savings over the course of a year.

At Industrial Air Services, we’ve seen how setting clear, realistic efficiency goals early in the year helps facilities reduce energy costs, improve reliability, and avoid emergency repairs later on. The key is focusing on practical goals that actually match how your system operates, not generic benchmarks.

Start by Establishing a Baseline

Before setting goals, you need to know where you’re starting.

A baseline should answer questions like:

• How many hours does the compressor run each day?

• How often does it load and unload?

• What is the normal operating pressure?

• Are there recurring moisture or pressure issues?

• How much energy is being used to produce compressed air?

Without a baseline, it’s impossible to measure improvement — or know if changes are actually working.

Focus on Reducing Waste Before Adding Equipment

Many efficiency gains come from eliminating waste, not buying new equipment.

Common waste areas include:

• Air leaks

• Excessive system pressure

• Short-cycling

• Poor drainage

• Dirty filters

• Inefficient controls

Addressing these first often delivers faster payback than major capital upgrades.

Set Pressure Reduction as an Early Goal

Pressure creep is one of the most common efficiency killers.

A realistic goal might be:

• Reducing system pressure by a few PSI

• Eliminating pressure increases used to mask problems

• Stabilizing pressure instead of constantly adjusting regulators

Lower pressure reduces energy use, leak loss, and stress on equipment.

Make Leak Reduction a Measurable Objective

Leak repair is one of the easiest efficiency wins.

Instead of treating leaks as a one-time project, set goals like:

• Reducing audible leaks throughout the plant

• Repairing leaks within a defined time frame

• Tracking recurring leak locations

• Scheduling periodic leak inspections

Leak management works best when it’s ongoing, not reactive.

Improve System Stability, Not Just Efficiency Numbers

Efficiency isn’t just about energy savings — it’s about consistency.

Good goals include:

• Reducing pressure fluctuations

• Eliminating frequent short-cycling

• Improving recovery time after demand spikes

• Stabilizing dryer performance and dew point

Stable systems tend to be more efficient by default.

Set Maintenance-Based Efficiency Goals

Maintenance plays a major role in efficiency.

Consider goals such as:

• Staying on schedule with filter and oil changes

• Keeping drains fully functional year-round

• Cleaning coolers and maintaining airflow

• Preventing moisture from reaching points of use

Well-maintained systems use less energy and fail less often.

Align Efficiency Goals With Production Needs

Efficiency should support production, not interfere with it.

Effective goals balance:

• Energy savings

• Reliability

• Capacity

• Product quality

The most successful efficiency plans improve performance while reducing cost — not one at the expense of the other.

Track Progress Throughout the Year

Efficiency goals only matter if they’re tracked.

Simple tracking can include:

• Monthly run-time checks

• Noting pressure adjustments

• Monitoring filter life

• Watching energy trends

• Logging service issues

Even basic tracking helps confirm that improvements are working.

Avoid Setting Goals That Rely on Guesswork

Efficiency goals should be based on data, not assumptions.

If you’re unsure where improvements will come from, a system evaluation can:

• Identify major inefficiencies

• Prioritize upgrades

• Estimate potential savings

• Help set realistic targets

Good goals are achievable and measurable.

Treat Efficiency as a Year-Long Process

Compressed air efficiency isn’t a one-time project.

The best results come from:

• Small, consistent improvements

• Regular system reviews

• Adjusting goals as production changes

• Preventing inefficiencies from creeping back in

Efficiency is easier to maintain than to rebuild.

A Strong Efficiency Plan Sets the Tone for the Year

Facilities that set compressed air efficiency goals early in the year tend to experience fewer breakdowns, lower operating costs, and more predictable performance. A little planning now prevents a lot of frustration later.

If you want help establishing a baseline, identifying efficiency opportunities, or setting practical goals for the year ahead, Industrial Air Services is ready to help.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

How Cold Weather Affects Compressed Air Performance

Cold weather doesn’t just affect people on the shop floor — it changes how compressed air systems behave, often in ways that aren’t immediately obvious. As temperatures drop, moisture behaves differently, equipment responds slower, and systems that ran fine in warmer months can suddenly start showing problems.

At Industrial Air Services, winter brings a noticeable shift in service calls across Middle Tennessee. Understanding how cold weather impacts compressed air performance helps facilities prevent downtime and avoid problems that tend to show up right when production is ramping back up.

Cold Air Holds Less Moisture — Until It’s Compressed

Cold outdoor air feels dry, but once it’s compressed and warmed inside the system, moisture becomes a problem.

During winter:

• Cold intake air warms rapidly during compression

• Water vapor condenses as air cools downstream

• Temperature swings increase condensation in piping and tanks

This often leads to more liquid water inside the system, not less.

Condensation Increases in Tanks and Piping

Cold surfaces encourage moisture to drop out of the air.

In winter, condensation tends to collect in:

• Receiver tanks

• Low points in piping

• Drop legs

• Filters and housings near exterior walls

If drainage isn’t working properly, that moisture gets pushed downstream once demand increases.

Drains Are More Likely to Freeze or Fail

Cold weather is especially hard on drains.

Problems often include:

• Frozen drain lines

• Sludge thickening in drain bodies

• Float mechanisms sticking

• Timers cycling incorrectly

A frozen or failed drain allows water to back up into the system, creating widespread moisture issues.

Dryers Work Harder Than Many People Expect

Dryers don’t get a break in winter.

Cold weather can cause:

• Refrigerated dryers to ice during low load

• Desiccant dryers to saturate faster

• Drain failures that go unnoticed

• Dew point instability during temperature swings

If dryers aren’t operating correctly, moisture problems appear quickly at points of use.

Pressure Stability Can Be Affected

Cold temperatures change air density and demand patterns.

In winter:

• Air tools may be used differently

• Valves cycle at different rates

• Equipment may start all at once after warm-up periods

These changes can cause pressure fluctuations, especially in systems with limited storage or undersized piping.

Oil Thickens in Cold Conditions

Cold temperatures affect oil viscosity.

Thicker oil can:

• Increase startup load

• Reduce lubrication effectiveness

• Raise operating temperatures

• Stress motors during startup

Using the correct oil and maintaining proper oil condition is especially important in winter.

Compressors May Run Hotter Despite Cold Air

This often surprises operators.

Even in cold weather, compressors can overheat due to:

• Restricted airflow

• Dirty coolers

• Higher run time compensating for leaks or moisture

• Increased pressure settings

Cold ambient temperatures don’t protect against overheating if other issues are present.

Moisture Damage Often Appears Later

Winter moisture problems don’t always show up immediately.

Damage can appear weeks later as:

• Rust flakes in filters

• Tool failures

• Corrosion inside piping

• Reduced dryer performance

By the time problems are obvious, moisture has often been present for a while.

Cold Weather Exposes Existing System Weaknesses

Winter doesn’t usually create new problems — it exposes existing ones.

Common weaknesses include:

• Poor drainage

• Marginal dryer capacity

• Inadequate storage

• Aging piping

• Undetected leaks

Cold weather simply makes these issues harder to ignore.

Winter Preparation Prevents Spring and Summer Problems

Moisture and corrosion that start in winter often cause problems later in the year.

Addressing cold-weather issues now helps:

• Reduce rust buildup

• Protect tools and equipment

• Improve dryer efficiency

• Prevent recurring moisture complaints

Winter maintenance pays dividends long after temperatures rise.

Cold Weather Doesn’t Have to Mean Cold Performance

Compressed air systems can run just as reliably in winter as they do in summer — but only if they’re prepared for seasonal conditions. Paying attention to moisture control, drainage, oil condition, and airflow during cold months prevents many of the problems that show up later.

If your facility has noticed new issues since temperatures dropped, Industrial Air Services can help identify what winter is revealing about your system.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

Why January Is the Best Time to Fix Air Leaks

Air leaks are one of the most expensive — and most ignored — problems in compressed air systems. They don’t stop production, they don’t usually trigger alarms, and they rarely feel urgent. But over time, leaks quietly drive up energy costs, shorten equipment life, and steal air capacity you’re already paying to produce.

January is one of the best times of the year to finally deal with them. Facilities that prioritize leak repair early in the year almost always see faster payback and fewer compressed air problems as the year goes on.

Colder Weather Makes Leaks Easier to Find

Winter conditions work in your favor.

Cold air increases the density difference between compressed air and the surrounding environment, making leaks:

• Louder

• Easier to feel by hand

• More visible through condensation or frost

• Easier to detect with ultrasonic tools

Leaks that were hard to notice in warmer months often stand out clearly in January.

Plants Are Often Quieter in Early January

Production schedules in early January are usually lighter or more controlled.

That makes it easier to:

• Hear hissing or whistling sounds

• Isolate sections of piping

• Identify leaks without background noise masking them

• Perform inspections without disrupting operations

A quieter plant makes leak detection faster and more accurate.

Fixing Leaks Early Frees Up Capacity for the Entire Year

Leaks steal air continuously.

Even small leaks force compressors to:

• Run longer

• Cycle more frequently

• Operate at higher pressure

• Consume more energy

Fixing leaks in January means you benefit from that recovered capacity for the rest of the year — not just during peak season.

Leak Repair Can Delay Costly Equipment Upgrades

Many facilities assume they need a larger compressor when demand increases.

In reality, leak repair often:

• Restores lost CFM

• Improves pressure stability

• Reduces short-cycling

• Lowers operating temperature

Addressing leaks first can delay or eliminate the need for expensive equipment upgrades.

January Leak Repair Supports Energy-Saving Goals

If reducing energy costs is a priority this year, leaks are the fastest place to start.

Leak repair:

• Produces immediate savings

• Requires minimal downtime

• Has one of the fastest returns on investment

• Improves overall system efficiency

Few improvements pay off as quickly as fixing leaks.

Leaks Get Worse Over Time If Ignored

Leaks don’t stay the same size forever.

Vibration, corrosion, and pressure cycles cause:

• Small leaks to grow

• Fittings to loosen further

• Hoses to crack

• Threaded joints to fail

Repairing leaks early prevents them from turning into larger, more expensive problems later in the year.

Winter Moisture Makes Leak Damage More Noticeable

Moisture and leaks often go hand in hand.

Leaks can:

• Pull moisture into the system

• Accelerate corrosion around fittings

• Create rust in piping and tools

• Increase filter saturation

Fixing leaks helps control moisture problems before humidity rises in spring and summer.

Leak Repair Improves Pressure Stability Immediately

Facilities often raise system pressure to compensate for leaks.

Once leaks are repaired:

• Pressure stabilizes

• Regulators can be set lower

• Tools perform more consistently

• Compressors don’t have to work as hard

This improves both performance and efficiency.

January Is a Good Time to Establish a Leak Management Plan

Leak repair shouldn’t be a one-time event.

Early in the year is the perfect time to:

• Identify high-leak areas

• Schedule periodic inspections

• Track recurring problem spots

• Create a simple leak repair routine

Consistent leak management prevents problems from building back up.

Leak Repair Reduces Wear on the Entire System

Every leak adds unnecessary stress.

Reducing leaks helps:

• Lower compressor run time

• Reduce heat

• Extend filter and oil life

• Protect dryers and controls

The entire system benefits when leaks are addressed.

Fixing Leaks in January Pays Off All Year Long

Leaks quietly drain money month after month. Fixing them early in the year ensures you’re not paying that penalty all year long. January offers the ideal combination of cooler temperatures, quieter operations, and fresh budgets — making it the perfect time to act.

If your facility hasn’t had a recent leak inspection, Industrial Air Services can help identify and repair leaks so your compressed air system starts the year running efficiently.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

The First Compressed Air Checks Every Facility Should Do in January

January is the reset button for most facilities. Production schedules normalize, staffing returns to full strength, and systems that coasted through the holidays are suddenly expected to perform at full capacity again. For compressed air systems, this is the most important time of the year to check in and make sure everything is ready for what’s ahead.

At Industrial Air Services, we see the same pattern every January across Middle Tennessee. Facilities that take a little time to inspect their air systems early in the month avoid many of the problems that show up later as downtime, rising energy costs, or emergency repairs. These first checks don’t require major shutdowns — just attention.

Start With a Quick System Walk-Through

Before pulling data or making adjustments, walk the system.

Look for water around tanks or drains, oil spots under compressors or filters, rust forming on piping or receivers, loose hoses or fittings, and anything that looks different than it did last year. January is a great time to catch problems that quietly developed during the holidays.

Listen for Air Leaks While the Plant Is Quiet

Early January is often quieter than peak production months.

That makes it easier to hear leaks at quick-connect fittings, hoses, regulators, valves, and older threaded joints. Even small leaks add up quickly over time, and fixing them early frees up capacity for the rest of the year.

Check Drain Operation Immediately

Cold weather and downtime are hard on drains.

Make sure automatic drains are cycling, manual drains are clear, and no condensate is backing up into tanks or piping. January moisture problems almost always trace back to drains that failed quietly during the holidays.

Look Closely at Moisture Control

Winter conditions create unique moisture challenges.

Check filters and points of use for water, verify dryer performance, and confirm dew point is stable. If moisture is present now, it will almost certainly get worse once humidity rises later in the year.

Review Pressure Settings Before Production Ramps Up

Pressure settings tend to drift over time.

Ask whether system pressure is higher than necessary, whether it was raised temporarily and never reset, and whether pressure could be reduced once leaks or restrictions are addressed. Lowering pressure early in the year can deliver immediate energy savings.

Watch Compressor Run Behavior

January is a good time to establish a baseline.

Pay attention to how long the compressor runs, how often it cycles, and whether it stays loaded during low demand. Changes in run behavior often point to leaks, rising demand, or control issues that need attention sooner rather than later.

Inspect Filters and Service Items

Filters that clogged late last year may already be affecting performance.

Check intake filters, oil filters, separator elements, and inline filtration. Starting the year with clean filters improves efficiency, reduces pressure drop, and helps compressors run cooler.

Check Ventilation and Cooler Cleanliness

Winter doesn’t eliminate overheating risk.

Dust, debris, and restricted airflow still cause problems. Make sure coolers are clean, fans are working properly, and hot air isn’t recirculating back into the compressor room.

Confirm Controls and Alarms Are Enabled

Temporary settings made during downtime often get forgotten.

Verify alarms are active, control logic is set correctly, sequencing hasn’t been altered unnecessarily, and manual overrides have been removed. Controls should reflect normal production conditions, not holiday operation.

Note Small Issues Before They Become Big Ones

January checks aren’t about fixing everything at once.

They’re about identifying:

• Small leaks

• Early moisture issues

• Pressure instability

• Rising run times

• Components nearing service intervals

Documenting these early makes planning much easier throughout the year.

January Sets the Tone for the Whole Year

Compressed air systems rarely improve on their own. Small inefficiencies discovered in January often turn into year-long problems if they’re ignored. A few simple checks now can prevent months of frustration later.

If you want help reviewing your system or establishing a clean baseline for the year, Industrial Air Services is ready to help you start strong.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

Early Warning Signs Your Compressed Air System Will Struggle in the New Year

Compressed air systems rarely fail without warning. More often, they start showing small signs that something isn’t right — signs that are easy to overlook during busy production periods. As the new year begins and production ramps back up, those subtle issues can quickly turn into downtime, higher energy costs, and emergency repairs.

At Industrial Air Services, many January service calls come from systems that were already struggling before the holidays. The signs were there — they just hadn’t reached a breaking point yet. Recognizing these early warning signals gives you a chance to fix problems before they disrupt your operation.

The Compressor Is Running Longer Than It Used To

One of the clearest warning signs is increased run time.

If your compressor:

• Runs longer to maintain the same pressure

• Rarely shuts off during normal operation

• Stays loaded even during lighter demand

…it often indicates leaks, rising demand, control issues, or restrictions in the system. Longer run times translate directly into higher energy costs and accelerated wear.

System Pressure Has Slowly Crept Up

Pressure creep is a classic sign of hidden problems.

Pressure is often raised to compensate for:

• Pressure drop at points of use

• Undersized piping

• Dirty filters

• Inadequate storage

Higher pressure may keep production moving, but it masks the real issue while increasing energy use and stress on equipment.

Moisture Is Showing Up Where It Shouldn’t

Water at tools, filters, or equipment is never a good sign.

Moisture issues often point to:

• Dryers struggling to keep up

• Failed or clogged drains

• Poor airflow or ventilation

• Condensation from temperature swings

If moisture appeared late last year, it’s likely to get worse as demand increases.

Filters Are Plugging Faster Than Normal

Filters don’t clog overnight.

If you’re replacing filters more often than expected, it usually means:

• Increased moisture load

• Oil carryover

• Rust or debris from piping

• Higher airflow than the system was designed for

Rapid filter saturation increases pressure drop and forces the compressor to work harder.

The Compressor Is Running Hotter

Rising operating temperature is a serious warning sign.

Higher temperatures are often caused by:

• Dirty coolers

• Poor ventilation

• Clogged filters

• Excessive run time

• High ambient temperatures

Heat accelerates oil breakdown and component wear, increasing the likelihood of failure.

Pressure Fluctuates During Normal Operation

Pressure should be stable during routine production.

If pressure:

• Drops suddenly when equipment starts

• Swings during steady demand

• Requires frequent regulator adjustments

…it usually points to storage, piping, or control problems that will worsen as production ramps up.

You’re Hearing More Alarms or Seeing More Faults

Alarms don’t usually increase without reason.

Frequent alarms may indicate:

• Overheating

• Pressure instability

• Electrical stress

• Moisture-related issues

Ignoring alarms allows small problems to turn into major failures.

Energy Costs Are Rising Without a Clear Cause

Many facilities notice higher energy bills in January and assume it’s seasonal.

In reality, compressed air inefficiencies often show up as:

• Longer run times

• Higher demand charges

• Increased cycling

• Elevated pressure settings

If production hasn’t increased but energy use has, compressed air is often the culprit.

Temporary Fixes Have Become Permanent

Short-term solutions tend to linger.

Examples include:

• Bypassed drains

• Disabled alarms

• Manual overrides

• Raised pressure setpoints

These workarounds often signal underlying issues that haven’t been addressed and will eventually cause problems.

Maintenance Is Becoming Reactive Instead of Planned

If maintenance feels like it’s constantly responding to issues instead of preventing them, it’s a sign the system is drifting toward failure.

Frequent small repairs often precede larger breakdowns if root causes aren’t addressed.

The System Hasn’t Been Evaluated in a Long Time

Compressed air systems evolve quietly.

Demand grows, equipment ages, and inefficiencies accumulate. If your system hasn’t been evaluated recently, early warning signs can go unnoticed until they become costly.

Early Action Prevents Year-Long Problems

The start of the year is one of the best times to address compressed air issues. Small adjustments made now can prevent months of inefficiency, downtime, and emergency repairs.

If you’re seeing any of these warning signs, a system evaluation can help identify what’s causing them and what should be addressed first.

Industrial Air Services can help you start the year with a compressed air system that’s stable, efficient, and ready to support production.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

Why Your Compressed Air System Should Be Evaluated After the Holidays

The period right after the holidays is one of the most overlooked — and most important — times to evaluate a compressed air system. Many facilities experience reduced staffing, partial shutdowns, or altered production schedules in late December. When everything starts back up in January, systems are suddenly asked to perform at full capacity again, often revealing problems that weren’t obvious before.

At Industrial Air Services, we see a noticeable uptick in service calls across Middle Tennessee in early January. In many cases, the issues didn’t start in January — they just became visible once normal operations resumed. A post-holiday system evaluation helps catch these problems early, before they turn into downtime.

Holiday Shutdowns Change How Air Systems Behave

Even short shutdowns can affect compressed air systems more than most people expect.

During holiday periods:

• Compressors may sit idle for days

• Airflow patterns change

• Moisture settles instead of moving through the system

• Drains may not cycle as frequently

• Temperature swings increase condensation

When production ramps back up, these changes can show up as pressure instability, moisture problems, or unexpected alarms.

Leaks Often Go Unnoticed During Downtime

Air leaks don’t stop just because production slows.

In fact, leaks can become harder to detect when:

• Fewer tools are running

• Background noise is lower

• Compressors cycle differently

• Pressure settings remain unchanged

Once normal demand returns, those same leaks force compressors to work harder, increasing run time and energy costs. A post-holiday evaluation helps identify leaks before they become a problem for the rest of the year.

Moisture Buildup Is Common After Idle Periods

Moisture is one of the biggest risks during downtime.

When systems sit:

• Condensate collects in tanks and low points

• Drains may clog or stick

• Cold weather increases condensation

• Dryers may not operate as consistently

Water that builds up during downtime often gets pushed downstream once the system restarts, leading to wet air at tools and equipment.

Controls and Settings Can Drift Over Time

During slower periods, it’s common for settings to get adjusted temporarily and never changed back.

This can include:

• Higher pressure setpoints

• Disabled alarms

• Manual overrides

• Altered load/unload behavior

A system evaluation after the holidays ensures controls are set correctly for normal production, not temporary conditions.

Energy Use Can Spike Without Obvious Reasons

Many facilities see energy costs rise in January and assume it’s weather-related.

In reality, post-holiday inefficiencies often include:

• Longer compressor run times

• Increased cycling

• Higher pressure than necessary

• Moisture-related pressure drop

Evaluating the system early helps prevent energy waste from becoming the new normal.

Wear and Tear Doesn’t Pause for the Holidays

Even when compressors aren’t running, components still age.

Oil can absorb moisture, seals can dry out, drains can clog, and electrical components can be affected by temperature swings. A post-holiday check helps identify wear before it leads to failures during peak production.

Small Issues Are Easier to Fix Before Production Is in Full Swing

Early January often offers a brief window before schedules fully fill up.

Addressing issues now means:

• Less disruption to operations

• More flexibility for scheduling repairs

• Lower risk of emergency downtime

• Better planning for the year ahead

Waiting until problems cause shutdowns usually costs more and creates more stress.

A System Evaluation Sets the Tone for the Year

A compressed air system rarely improves on its own.

Starting the year with an evaluation helps:

• Establish a performance baseline

• Identify priorities for maintenance or upgrades

• Reduce emergency calls

• Improve reliability and efficiency

• Support production goals instead of limiting them

It’s one of the simplest ways to start the year proactively.

Don’t Let Post-Holiday Problems Linger All Year

Many air system issues discovered in January stay unresolved for months, quietly driving up costs and wear. A post-holiday evaluation helps catch those problems early, when they’re easiest to fix.

If your facility is getting back into full production after the holidays, this is the ideal time to take a fresh look at your compressed air system.

Industrial Air Services can help you evaluate performance, identify hidden issues, and make sure your system is ready for the year ahead.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

Why Your Compressed Air System Should Be Evaluated After the Holidays

The period right after the holidays is one of the most overlooked — and most important — times to evaluate a compressed air system. Many facilities experience reduced staffing, partial shutdowns, or altered production schedules in late December. When everything starts back up in January, systems are suddenly asked to perform at full capacity again, often revealing problems that weren’t obvious before.

At Industrial Air Services, we see a noticeable uptick in service calls across Middle Tennessee in early January. In many cases, the issues didn’t start in January — they just became visible once normal operations resumed. A post-holiday system evaluation helps catch these problems early, before they turn into downtime.

Holiday Shutdowns Change How Air Systems Behave

Even short shutdowns can affect compressed air systems more than most people expect.

During holiday periods:

• Compressors may sit idle for days

• Airflow patterns change

• Moisture settles instead of moving through the system

• Drains may not cycle as frequently

• Temperature swings increase condensation

When production ramps back up, these changes can show up as pressure instability, moisture problems, or unexpected alarms.

Leaks Often Go Unnoticed During Downtime

Air leaks don’t stop just because production slows.

In fact, leaks can become harder to detect when:

• Fewer tools are running

• Background noise is lower

• Compressors cycle differently

• Pressure settings remain unchanged

Once normal demand returns, those same leaks force compressors to work harder, increasing run time and energy costs. A post-holiday evaluation helps identify leaks before they become a problem for the rest of the year.

Moisture Buildup Is Common After Idle Periods

Moisture is one of the biggest risks during downtime.

When systems sit:

• Condensate collects in tanks and low points

• Drains may clog or stick

• Cold weather increases condensation

• Dryers may not operate as consistently

Water that builds up during downtime often gets pushed downstream once the system restarts, leading to wet air at tools and equipment.

Controls and Settings Can Drift Over Time

During slower periods, it’s common for settings to get adjusted temporarily and never changed back.

This can include:

• Higher pressure setpoints

• Disabled alarms

• Manual overrides

• Altered load/unload behavior

A system evaluation after the holidays ensures controls are set correctly for normal production, not temporary conditions.

Energy Use Can Spike Without Obvious Reasons

Many facilities see energy costs rise in January and assume it’s weather-related.

In reality, post-holiday inefficiencies often include:

• Longer compressor run times

• Increased cycling

• Higher pressure than necessary

• Moisture-related pressure drop

Evaluating the system early helps prevent energy waste from becoming the new normal.

Wear and Tear Doesn’t Pause for the Holidays

Even when compressors aren’t running, components still age.

Oil can absorb moisture, seals can dry out, drains can clog, and electrical components can be affected by temperature swings. A post-holiday check helps identify wear before it leads to failures during peak production.

Small Issues Are Easier to Fix Before Production Is in Full Swing

Early January often offers a brief window before schedules fully fill up.

Addressing issues now means:

• Less disruption to operations

• More flexibility for scheduling repairs

• Lower risk of emergency downtime

• Better planning for the year ahead

Waiting until problems cause shutdowns usually costs more and creates more stress.

A System Evaluation Sets the Tone for the Year

A compressed air system rarely improves on its own.

Starting the year with an evaluation helps:

• Establish a performance baseline

• Identify priorities for maintenance or upgrades

• Reduce emergency calls

• Improve reliability and efficiency

• Support production goals instead of limiting them

It’s one of the simplest ways to start the year proactively.

Don’t Let Post-Holiday Problems Linger All Year

Many air system issues discovered in January stay unresolved for months, quietly driving up costs and wear. A post-holiday evaluation helps catch those problems early, when they’re easiest to fix.

If your facility is getting back into full production after the holidays, this is the ideal time to take a fresh look at your compressed air system.

Industrial Air Services can help you evaluate performance, identify hidden issues, and make sure your system is ready for the year ahead.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

Why Your Compressed Air System Should Be Evaluated After the Holidays

The period right after the holidays is one of the most overlooked — and most important — times to evaluate a compressed air system. Many facilities experience reduced staffing, partial shutdowns, or altered production schedules in late December. When everything starts back up in January, systems are suddenly asked to perform at full capacity again, often revealing problems that weren’t obvious before.

At Industrial Air Services, we see a noticeable uptick in service calls across Middle Tennessee in early January. In many cases, the issues didn’t start in January — they just became visible once normal operations resumed. A post-holiday system evaluation helps catch these problems early, before they turn into downtime.

Holiday Shutdowns Change How Air Systems Behave

Even short shutdowns can affect compressed air systems more than most people expect.

During holiday periods:

• Compressors may sit idle for days

• Airflow patterns change

• Moisture settles instead of moving through the system

• Drains may not cycle as frequently

• Temperature swings increase condensation

When production ramps back up, these changes can show up as pressure instability, moisture problems, or unexpected alarms.

Leaks Often Go Unnoticed During Downtime

Air leaks don’t stop just because production slows.

In fact, leaks can become harder to detect when:

• Fewer tools are running

• Background noise is lower

• Compressors cycle differently

• Pressure settings remain unchanged

Once normal demand returns, those same leaks force compressors to work harder, increasing run time and energy costs. A post-holiday evaluation helps identify leaks before they become a problem for the rest of the year.

Moisture Buildup Is Common After Idle Periods

Moisture is one of the biggest risks during downtime.

When systems sit:

• Condensate collects in tanks and low points

• Drains may clog or stick

• Cold weather increases condensation

• Dryers may not operate as consistently

Water that builds up during downtime often gets pushed downstream once the system restarts, leading to wet air at tools and equipment.

Controls and Settings Can Drift Over Time

During slower periods, it’s common for settings to get adjusted temporarily and never changed back.

This can include:

• Higher pressure setpoints

• Disabled alarms

• Manual overrides

• Altered load/unload behavior

A system evaluation after the holidays ensures controls are set correctly for normal production, not temporary conditions.

Energy Use Can Spike Without Obvious Reasons

Many facilities see energy costs rise in January and assume it’s weather-related.

In reality, post-holiday inefficiencies often include:

• Longer compressor run times

• Increased cycling

• Higher pressure than necessary

• Moisture-related pressure drop

Evaluating the system early helps prevent energy waste from becoming the new normal.

Wear and Tear Doesn’t Pause for the Holidays

Even when compressors aren’t running, components still age.

Oil can absorb moisture, seals can dry out, drains can clog, and electrical components can be affected by temperature swings. A post-holiday check helps identify wear before it leads to failures during peak production.

Small Issues Are Easier to Fix Before Production Is in Full Swing

Early January often offers a brief window before schedules fully fill up.

Addressing issues now means:

• Less disruption to operations

• More flexibility for scheduling repairs

• Lower risk of emergency downtime

• Better planning for the year ahead

Waiting until problems cause shutdowns usually costs more and creates more stress.

A System Evaluation Sets the Tone for the Year

A compressed air system rarely improves on its own.

Starting the year with an evaluation helps:

• Establish a performance baseline

• Identify priorities for maintenance or upgrades

• Reduce emergency calls

• Improve reliability and efficiency

• Support production goals instead of limiting them

It’s one of the simplest ways to start the year proactively.

Don’t Let Post-Holiday Problems Linger All Year

Many air system issues discovered in January stay unresolved for months, quietly driving up costs and wear. A post-holiday evaluation helps catch those problems early, when they’re easiest to fix.

If your facility is getting back into full production after the holidays, this is the ideal time to take a fresh look at your compressed air system.

Industrial Air Services can help you evaluate performance, identify hidden issues, and make sure your system is ready for the year ahead.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086

Planning Your Compressed Air Upgrades for the New Year

The new year is one of the few times facilities get a true reset. Budgets refresh, production goals shift, and there’s finally space to step back and look at what’s really happening on the floor. When it comes to compressed air, planning upgrades ahead of time — instead of reacting to breakdowns — almost always leads to better results, lower costs, and fewer headaches.

At Industrial Air Services, we work with facilities across Middle Tennessee that want compressed air to be reliable, predictable, and efficient, not a constant source of disruption. Planning upgrades early in the year makes that possible.

Start With What Caused Problems Last Year

Before thinking about new equipment, look back at where the system struggled.

Ask yourself:

• Where did pressure drop show up?

• When did moisture become an issue?

• How often did the compressor overheat or alarm?

• Were emergency service calls needed?

• Did air issues ever slow or stop production?

The problems you dealt with last year should guide what gets addressed first in the new one.

Fix the System Before Replacing the Compressor

One of the most common mistakes facilities make is replacing a compressor without fixing the system around it.

In many cases, the real problems are:

• Air leaks

• Undersized or poorly routed piping

• Not enough air storage

• Poor ventilation

• Overloaded dryers or clogged filters

Correcting these issues first allows your existing compressor — or a future replacement — to run efficiently instead of compensating for hidden system flaws.

Prioritize Energy-Saving Improvements

Compressed air is one of the most expensive utilities in most facilities.

High-impact upgrades often include:

• Leak detection and repair

• Reducing system pressure

• Adding or relocating receiver tanks

• Improving controls or sequencing

• Evaluating whether a variable-speed compressor makes sense

Many of these improvements deliver fast payback and continue saving money year after year.

Plan for Growth, Not Just Today’s Demand

Air demand rarely stays the same.

Consider:

• New tools or equipment

• Added shifts

• Higher production volumes

• Future expansion plans

Designing upgrades with growth in mind prevents short-term fixes that become long-term problems.

Address Moisture Issues at the Source

If water showed up in your system last year, it’s a sign something needs attention.

Moisture problems often point to:

• Dryers that are undersized or overloaded

• Failed or poorly placed drains

• Inadequate storage

• Piping layouts that trap condensate

Fixing moisture control early protects tools, piping, and product quality throughout the year.

Don’t Ignore Piping Limitations

Old or undersized piping quietly limits everything else in the system.

Signs piping should be part of your upgrade plan include:

• Pressure loss at the far end of the plant

• Frequent leaks in the same areas

• Rust or debris showing up in filters

• Excessive noise or vibration

Modern piping upgrades often improve performance immediately without touching the compressor.

Build Redundancy Into the Plan

If your operation depends on compressed air, downtime is costly.

Planning ahead allows you to consider:

• Backup or secondary compressors

• Rental connection points

• Load-sharing strategies

• Emergency response plans

Even limited redundancy can keep production moving when unexpected problems occur.

Schedule Work During Planned Downtime

One of the biggest advantages of planning upgrades early is control.

Instead of reacting to failures:

• Schedule work during slower production periods

• Coordinate upgrades around operations

• Avoid after-hours emergency labor

• Reduce stress on maintenance teams

Planned work is safer, cleaner, and more cost-effective.

Create a Phased Upgrade Roadmap

Not everything has to happen at once.

A realistic plan might include:

• Early-year leak repair and filter replacement

• Mid-year storage or ventilation improvements

• Later-year piping or dryer upgrades

• Future compressor or control upgrades

A phased approach keeps costs manageable while making steady progress.

Get a System Evaluation Before Finalizing Decisions

The best upgrade plans are based on real system data, not assumptions.

A system evaluation can help identify:

• Where air is being wasted

• Which upgrades will deliver the biggest return

• What issues are urgent versus long-term

• How to prioritize spending

This ensures upgrade dollars go where they’ll have the most impact.

A Planned Year Means Fewer Surprises

Facilities that plan compressed air upgrades early experience fewer breakdowns, lower operating costs, and far less stress throughout the year. Thoughtful planning turns compressed air into a dependable utility instead of an ongoing concern.

If you’re planning upgrades for the new year and want help building a practical, step-by-step plan, Industrial Air Services is ready to help.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

How Preventive Maintenance Reduces Emergency Repairs

Emergency compressor repairs almost never happen at a convenient time. They tend to show up late at night, on weekends, or right in the middle of a production run. When compressed air goes down, production usually slows or stops altogether, and the focus quickly shifts from efficiency to urgency.

At Industrial Air Services, we see this pattern every year across Middle Tennessee. Many emergency calls trace back to issues that were visible long before the failure happened. Preventive maintenance isn’t just about keeping equipment running — it’s about avoiding stress, downtime, and unnecessary repair costs.

Most Emergency Repairs Start as Small Issues

Major compressor failures rarely come out of nowhere. They usually begin with small, manageable problems that go unchecked.

These often include dirty filters, oil breaking down, drains sticking or failing, small air leaks, or operating temperatures creeping higher over time. Preventive maintenance catches these issues early, while they’re still easy and affordable to correct.

Planned Service Prevents After-Hours Breakdowns

Emergency repairs often happen outside normal business hours, when labor costs are higher and options are limited. Planned maintenance happens on your schedule, not the compressor’s.

Addressing issues during scheduled service windows helps avoid premium labor rates, rushed decisions, and unnecessary disruption to operations.

Preventive Maintenance Helps Compressors Run Cooler

Heat is one of the most common contributors to compressor failure.

Routine maintenance helps control temperature by keeping filters clean, coolers free of debris, oil at proper levels, and airflow unobstructed. Compressors that run cooler experience less stress and tend to last longer.

Routine Inspections Catch Wear Before Failure Occurs

Many compressor components wear gradually and predictably.

Belts, filters, separator elements, bearings, and electrical components all have service intervals. Preventive maintenance replaces these parts before they fail unexpectedly and cause secondary damage that leads to larger repairs.

Maintenance Reduces the Risk of Major Air-End Damage

Air-end repairs are among the most expensive compressor failures a facility can face.

They are often caused by oil contamination, poor lubrication, overheating, or extended operation under stress. Regular oil changes, filter replacement, and inspections dramatically reduce the likelihood of these high-cost failures.

Maintained Systems Are Easier and Faster to Repair

Even well-maintained systems can experience issues, but when maintenance is consistent, problems are easier to diagnose.

Technicians can identify root causes more quickly, avoid compounding problems, and restore operation safely. This shortens downtime and lowers overall repair costs.

Preventive Maintenance Protects Downstream Equipment

Emergency compressor failures often affect more than just the compressor itself.

Moisture, oil carryover, and pressure instability can damage dryers, saturate filters, accelerate piping corrosion, and harm air tools or production equipment. Maintaining the entire system helps prevent these cascading problems.

Predictable Maintenance Costs Beat Surprise Repair Bills

Emergency repairs are unpredictable and hard to budget for.

Preventive maintenance allows facilities to plan expenses, schedule service strategically, and avoid panic spending. Over time, planned maintenance almost always costs less than repeated emergency repairs.

Preventive Maintenance Extends Equipment Life

Compressors that receive regular service tend to run more efficiently, experience fewer breakdowns, and deliver more consistent performance.

Extending equipment life by even a few years can provide significant return on investment and delay costly replacements.

Preventive Maintenance Improves Safety

Unexpected compressor failures can create unsafe conditions, including sudden pressure loss, overheated components, electrical issues, or slippery floors caused by oil or condensate.

Routine inspections reduce the likelihood of these safety risks developing unnoticed.

Preventing Emergencies Is Always the Better Option

Preventive maintenance isn’t about fixing what’s broken — it’s about keeping problems from occurring at the worst possible time. Facilities that invest in routine service experience fewer emergencies, lower repair costs, and far less downtime.

If emergency compressor repairs have become a pattern, it’s often a sign that maintenance needs to shift from reactive to proactive.

If you’re looking to reduce emergency calls and gain more control over your compressed air system, Industrial Air Services is here to help.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

Common Compressed Air Mistakes Facilities Plan to Fix Next Year

As the year comes to a close, many facilities start taking an honest look at what worked, what didn’t, and what they want to improve going forward. When it comes to compressed air systems, the same issues tend to rise to the top year after year. They’re not always urgent, but they quietly increase costs, create inefficiencies, and lead to avoidable downtime.

At Industrial Air Services, we hear the same refrains every December from facilities across Middle Tennessee: “We’ve been meaning to address that,” or “That’s something we need to fix next year.” Here are the most common compressed air mistakes facilities plan to correct — and why it makes sense to finally tackle them.

Running the System at Higher Pressure Than Necessary

This is one of the most common habits facilities want to undo.

Pressure often gets turned up to compensate for pressure drop, leaks, growing demand, or undersized piping. While it may keep tools running, higher pressure increases energy consumption, worsens leaks, and adds unnecessary strain to equipment. Many facilities plan to lower system pressure once the real issues are addressed.

Ignoring Small Air Leaks

Small leaks are easy to ignore because production keeps moving.

They’re often left alone because the compressor still keeps up and no one feels an immediate impact. Over time, though, those leaks force the compressor to run longer and hotter, driving up energy costs. Fixing leaks is one of the fastest ways facilities free up air capacity heading into the new year.

Relying on Emergency Repairs Instead of Preventive Maintenance

Reactive maintenance is stressful and expensive.

Facilities often decide they want to move away from after-hours service calls, weekend breakdowns, rushed decisions, and unplanned downtime. Preventive maintenance helps stabilize costs, reduce emergencies, and keep compressors running efficiently throughout the year.

Living With Inconsistent Pressure

Pressure fluctuations often become accepted as “normal.”

Operators adjust regulators or work around weak tools instead of fixing the underlying problem. Inconsistent pressure usually points to issues with storage, piping, or controls — issues many facilities plan to finally address rather than compensate for.

Putting Off Piping Upgrades Too Long

Old or undersized piping quietly limits performance.

Pressure drop, moisture problems, rust contamination, frequent leaks, and excessive noise often trace back to aging piping. Many facilities know piping is part of the problem but delay upgrades because the system still works. By year-end, it often becomes clear that a long-term fix is overdue.

Accepting Moisture as Part of the System

Water in compressed air should never be considered normal.

Facilities often justify moisture by saying it only happens part of the year or that tanks get drained “when someone remembers.” Over time, moisture leads to corrosion, tool damage, and product issues. Many facilities plan to address moisture properly through better dryers, drains, and storage.

Not Tracking System Performance

Many compressed air systems operate with little visibility.

Without tracking run hours, load versus unload time, pressure trends, or energy use, inefficiencies go unnoticed. Gaining better insight into system performance is a common goal for the new year.

Delaying Air Storage Improvements

Undersized or poorly placed receiver tanks cause short-cycling, pressure instability, dryer overload, and increased energy use. Storage upgrades are often postponed, but many facilities plan to add or relocate tanks once they see how much storage affects efficiency.

Operating With No Backup Air Plan

Single-compressor systems carry significant risk.

Facilities often realize that a single failure could shut down production and that emergency rentals aren’t always immediately available. Planning some level of backup air becomes a priority heading into the new year.

Waiting Too Long to Evaluate the Whole System

Compressed air systems evolve quietly.

Demand grows, equipment ages, and temporary fixes become permanent. By the end of the year, many facilities recognize that a system evaluation would help prioritize improvements and avoid repeating the same problems next year.

The New Year Is the Right Time to Reset

Most compressed air mistakes don’t come from neglect — they come from growth, changing production needs, and short-term fixes that stuck around too long. The new year offers a clean slate to reset habits and build a system that runs more efficiently and reliably.

If your facility has a compressed air improvement list for the coming year, Industrial Air Services can help you prioritize it and turn plans into practical upgrades.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

Year-End Compressed Air Maintenance Checklist

The end of the year is one of the best times to take a closer look at your compressed air system. Production often slows down, holiday schedules create small pockets of downtime, and maintenance teams finally have a chance to address issues that get pushed aside during busy months. A little attention now can prevent unexpected breakdowns and costly emergency repairs when production ramps back up in the new year.

At Industrial Air Services, we encourage facilities across Middle Tennessee to treat year-end as a reset point — not just for budgets and planning, but for their compressed air systems too. This checklist highlights the most important areas to review before the calendar turns.

Start With a Walk-Through

Before touching anything, take a slow walk through the system.

Look for oil spots under compressors or filters, water around drains or tanks, rust on piping or receiver tanks, loose hoses or fittings, excessive vibration, unusual noise, or recurring alarms. Many problems are visible once you slow down long enough to notice them.

Pay Attention to Compressor Run Behavior

How your compressor runs tells you a lot about system health.

Watch for constant operation even during low demand, frequent short-cycling, long unloaded run times, or unexpected shutdowns. Changes in run behavior usually point to leaks, rising demand, control issues, or airflow problems.

Inspect and Replace Filters

Filters work quietly in the background, but when they clog, efficiency drops quickly.

Year-end is a great time to replace intake air filters, oil filters, separator elements, and inline particulate or coalescing filters. Clean filters reduce pressure drop, lower energy use, and help the compressor run cooler.

Drain Receiver Tanks and Verify Drain Operation

Receiver tanks collect water all year long, especially in humid climates.

Make sure wet tanks are fully drained, automatic drains are cycling properly, drain lines are clear, and no water is backing up into the system. Leaving water in tanks over winter accelerates corrosion and moisture problems.

Check Dryer Performance

Dryers work hardest when humidity fluctuates, which is common this time of year.

Confirm the dew point is stable, drains are operating correctly, refrigerated dryers are cooling properly, and desiccant dryers show no signs of saturation or channeling. If moisture is getting downstream, it’s better to deal with it now than during peak production.

Clean Coolers and Improve Ventilation

Dust, dirt, and debris slowly restrict airflow.

Year-end is a good time to clean compressor coolers, check fan operation, remove obstructions near ventilation openings, and make sure hot air is not recirculating. Better airflow helps prevent overheating and improves efficiency.

Check Oil Condition and Levels

Oil condition offers valuable insight into compressor health.

Verify oil levels are correct and look for oil that appears dark, burnt, or foamy. If oil condition looks questionable, replacing it now helps prevent cold-weather and startup issues later.

Inspect Piping and Leak-Prone Areas

Leaks tend to multiply quietly over time.

Focus on quick-connect fittings, hose reels, regulators, drop legs, and older threaded connections. Fixing leaks now reduces energy waste immediately and lowers compressor run time going into the new year.

Review Pressure Settings

Pressure settings often creep up without anyone realizing it.

Ask whether system pressure is higher than necessary, whether pressure was increased to mask another issue, and whether it could be safely reduced after fixing leaks or filters. Even small pressure reductions can create noticeable energy savings.

Document Issues for the New Year

Not everything needs to be fixed immediately, but everything should be noted.

Create a list of aging equipment, recurring problems, planned upgrades, storage or piping concerns, and control improvements. This makes budgeting and planning much easier in the months ahead.

Schedule Preventive Service Before January

If your system hasn’t been serviced recently, year-end is the ideal time.

Preventive service helps catch small issues early, avoid emergency repairs, improve efficiency, extend equipment life, and start the new year with confidence. Planned maintenance is always easier — and less expensive — than emergency repairs.

A Strong Start to the New Year Begins Now

Compressed air systems don’t usually fail all at once. They wear down quietly over time. A year-end checklist helps reset the system, correct small issues, and head into January ready for whatever production brings.

If you’d like help working through this checklist or want a professional system evaluation before the new year, Industrial Air Services is ready to help.

Industrial Air Services
📞 (615) 641-3100
📍 138 Bain Drive • LaVergne, TN 37086
🌐 www.industrialairservice.com

How to Prepare Your Compressed Air System for Increased Production Demand

Increased production is usually a good problem to have — until the compressed air system can’t keep up. As demand rises, weaknesses that were barely noticeable before suddenly become major issues. Pressure drops, moisture shows up, compressors overheat, and downtime creeps in right when production matters most.

At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga prepare their compressed air systems for growth before it causes disruption. Whether demand is increasing seasonally, due to added shifts, or from new equipment, preparation makes all the difference.

Here’s how to get ahead of it.

Start by Understanding How Demand Will Change

Not all production increases affect air systems the same way.

Ask:

• Will air usage increase steadily or in short bursts?

• Are new machines cycling on and off?

• Will demand be higher all day or only during certain shifts?

• Are multiple tools starting simultaneously?

Understanding the pattern of demand is more important than knowing the peak number alone.

Verify Your Compressor Can Handle Sustained Load

A compressor that keeps up today may struggle tomorrow.

Signs your compressor may be nearing its limit include:

• Running continuously at full load

• Higher discharge temperatures

• Longer recovery times after demand spikes

• More frequent alarms or shutdowns

If the compressor is already working hard, increased demand will push it past safe operating limits.

Add or Reevaluate Air Storage Before Demand Increases

Storage is one of the easiest ways to prepare for higher demand.

Proper storage:

• Absorbs short bursts of air usage

• Reduces pressure drop during peak demand

• Prevents short-cycling

• Stabilizes system pressure

In many cases, adding storage delays or even eliminates the need for a larger compressor.

Check Dryer Capacity and Moisture Control

Higher airflow means more moisture entering the system.

When production increases:

• Dryers may become overloaded

• Dew point can rise

• Water may pass downstream

• Filters saturate faster

Confirm your dryer is sized for the new airflow, not last year’s conditions — especially in humid climates.

Inspect Piping for Restrictions and Pressure Drop

Increased demand exposes piping weaknesses quickly.

Look for:

• Undersized main headers

• Long runs with multiple elbows

• Corroded or rusted piping

• Areas with known pressure loss

Even a strong compressor can’t overcome restrictive piping without wasting energy.

Fix Air Leaks Before Demand Rises

Leaks consume capacity you’ll need later.

As production increases:

• Existing leaks become more costly

• Pressure drops faster

• Compressors run longer to compensate

Leak repair is one of the fastest and least expensive ways to free up air capacity.

Evaluate Controls and Sequencing

Controls that worked under lighter demand may struggle as usage increases.

Watch for:

• Compressors loading at the same time

• Frequent cycling

• Pressure swings during peak use

• Poor load sharing

Improved controls help the system respond smoothly instead of reacting late.

Plan for Redundancy and Backup Options

Increased demand raises the stakes when something goes wrong.

Preparation may include:

• A secondary or trim compressor

• Rental connection points

• Load-sharing strategies

• Emergency response planning

Even limited redundancy can prevent total shutdown during a failure.

Schedule Preventive Maintenance Ahead of the Ramp-Up

The worst time for maintenance issues is during peak production.

Before demand increases:

• Replace filters

• Clean coolers

• Verify drains

• Check oil condition

• Inspect belts and electrical components

Preventive service ensures the system is ready to work harder.

Monitor Performance Closely During the Transition

As production ramps up, watch system behavior carefully.

Track:

• Run time

• Load vs. unload patterns

• Pressure stability

• Temperature trends

• Moisture levels

Early data helps catch issues before they escalate.

Plan for Growth, Not Just the Immediate Increase

Short-term fixes can become long-term problems.

If demand is expected to continue growing:

• Design upgrades with expansion in mind

• Avoid temporary workarounds

• Build flexibility into the system

Planning now saves money and downtime later.

Preparing Your Air System Is Part of Preparing for Growth

Increased production shouldn’t come with increased stress. A compressed air system that’s ready for higher demand supports growth instead of limiting it.

If your facility is planning to ramp up production, add equipment, or increase shifts, we can evaluate your compressed air system and help you prepare before problems appear.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing system evaluations, capacity planning, upgrades, and full compressed air support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

Why Air Quality Standards Matter More Than You Think

Compressed air often gets treated as a utility — flip the switch and it’s there. But the quality of that air plays a much bigger role in production, equipment life, and product integrity than many facilities realize. Poor air quality doesn’t always cause immediate failures. Instead, it creates slow, expensive problems that show up as downtime, defects, and shortened equipment life.

At Industrial Air Services, we see air quality issues affecting facilities across Nashville, Knoxville, and Chattanooga, especially in operations where air requirements have evolved but the system hasn’t. Understanding air quality standards — and why they matter — helps prevent problems long before they reach the production floor.

Compressed Air Is Not Naturally Clean

Atmospheric air contains:

• Moisture

• Dust

• Dirt

• Oil vapor

• Microorganisms

When air is compressed, those contaminants become concentrated. Without proper treatment, they move directly into your tools, machines, and processes.

Air Quality Directly Affects Equipment Life

Contaminated air accelerates wear.

Poor air quality causes:

• Corrosion inside tools and cylinders

• Sticking valves and actuators

• Seal and O-ring damage

• Premature bearing failure

• Increased lubrication issues

Clean, dry air reduces friction and extends equipment life significantly.

Moisture Is the Most Common Air Quality Problem

Water in compressed air creates widespread issues:

• Rust in piping and tanks

• Filter saturation

• Tool malfunction

• Product contamination

• Freezing in cold conditions

Even small amounts of moisture can cause ongoing damage if not controlled properly.

Oil Carryover Creates Hidden Contamination

Oil mist that passes downstream:

• Coats internal surfaces

• Traps dirt and debris

• Degrades seals

• Affects sensitive processes

Oil contamination is especially damaging in industries where air contacts products directly or indirectly.

Air Quality Impacts Product Quality More Than Expected

In many processes, compressed air touches the product — even if indirectly.

Poor air quality can lead to:

• Surface defects

• Inconsistent finishes

• Product rejection

• Compliance issues

• Customer complaints

Food, beverage, packaging, electronics, and painting operations are especially sensitive.

ISO Air Quality Classes Exist for a Reason

ISO air quality standards define limits for:

• Particulates

• Moisture (dew point)

• Oil content

These standards aren’t arbitrary — they exist to ensure compressed air is suitable for its intended use. Operating outside appropriate air quality classes increases risk, even if problems aren’t immediately visible.

Tools Can Mask Air Quality Problems for a Long Time

Many facilities assume air quality is fine because tools still work.

In reality:

• Damage is happening internally

• Wear is accelerating quietly

• Failures are being delayed, not prevented

By the time tools start failing, air quality problems have often been present for months or years.

Dryers and Filters Must Match the Application

Not every operation needs the same air quality.

Air treatment should be selected based on:

• Process sensitivity

• Environmental conditions

• Required dew point

• Oil tolerance

• Operating pressure

Undersized or mismatched dryers and filters leave gaps in protection.

Air Quality Problems Often Get Worse as Systems Grow

As demand increases:

• Dryers get overloaded

• Filters see higher flow

• Moisture removal becomes less effective

• Pressure drop increases

Systems that once met air quality needs may no longer be adequate after growth or production changes.

Better Air Quality Reduces Maintenance Across the System

Improving air quality:

• Reduces tool repairs

• Extends filter life

• Protects piping

• Stabilizes pressure

• Improves dryer performance

Cleaner air lowers maintenance costs across the entire system — not just at the compressor.

Air Quality Issues Are Easier to Prevent Than Fix

Once corrosion, contamination, or damage has occurred, repairs are costly and disruptive. Preventing air quality problems through proper design and maintenance is far more efficient than reacting after failures happen.

Compressed Air Quality Is a Production Asset — Not an Afterthought

Air quality affects reliability, efficiency, product quality, and long-term operating cost. Facilities that treat air quality as part of their production process — not just a utility — experience fewer issues and better overall performance.

If you’re unsure whether your compressed air meets the needs of your operation, a system evaluation can identify gaps and recommend practical improvements before problems escalate.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing air quality assessments, filtration and dryer solutions, and full compressed air system support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

The Importance of Proper Compressor Sizing for Long-Term Reliability

When compressed air systems struggle, many facilities assume the compressor itself is the problem. In reality, the issue is often size, not condition. A compressor that’s too big or too small will never operate efficiently, no matter how new or well-maintained it is. Over time, improper sizing leads to higher energy costs, more breakdowns, and shorter equipment life.

At Industrial Air Services, we frequently evaluate systems across Nashville, Knoxville, and Chattanooga where compressors were sized based on assumptions, outdated needs, or “bigger must be better” logic. Here’s why proper sizing matters — and how getting it right protects your system long-term.

Oversized Compressors Create Hidden Problems

An oversized compressor may seem like a safe choice, but it often causes more harm than good.

Common issues include:

• Excessive unloading or short-cycling

• Higher energy use during idle time

• Poor oil temperature control

• Increased moisture carryover

• Premature wear on motors and controls

Large compressors rarely run at their most efficient point when demand is low or variable.

Undersized Compressors Are Always Under Stress

Compressors that are too small never get a break.

Signs of undersizing include:

• Continuous operation at full load

• High discharge temperatures

• Frequent alarms or shutdowns

• Inability to maintain pressure during peak demand

• Shortened service intervals

Running a compressor at maximum capacity nonstop drastically reduces its lifespan.

Sizing Directly Impacts Energy Consumption

Compressors are most efficient when operating within a specific load range.

Improper sizing causes:

• Excessive starts and stops

• Longer run times than necessary

• Increased amp draw

• Higher peak demand charges

Even a perfectly maintained compressor wastes energy if it’s the wrong size for the job.

Air Demand Is Rarely What You Think It Is

Many compressors are sized using:

• Nameplate ratings of tools

• Worst-case assumptions

• Old production data

• Future growth guesses

Actual air demand is often very different once measured. Without real data, systems are frequently mis-sized from day one.

Storage and Controls Affect Sizing Decisions

Compressor size doesn’t exist in isolation.

Proper sizing depends on:

• Air receiver capacity

• Control strategy

• Load profile

• Pressure stability

• Peak vs. average demand

In many cases, adding storage or improving controls allows a smaller compressor to perform better than a larger one.

Incorrect Sizing Accelerates Maintenance Costs

When compressors operate outside their ideal range:

• Filters clog faster

• Oil breaks down sooner

• Separators fail early

• Bearings wear prematurely

• Electrical components experience stress

This leads to more frequent service calls and higher long-term maintenance expenses.

System Growth Often Breaks Originally “Correct” Sizing

A compressor that was properly sized years ago may no longer be appropriate.

Common causes:

• Added shifts

• New equipment

• Expanded production lines

• Temporary fixes that became permanent

Regular system reviews help ensure compressor capacity still matches demand.

Proper Sizing Improves System Stability

Correctly sized compressors provide:

• Stable pressure

• Smooth load cycles

• Predictable performance

• Better dryer operation

• Improved air quality

Stability protects downstream equipment and improves production consistency.

Multiple Smaller Compressors Can Be Better Than One Large Unit

In many facilities, redundancy and flexibility matter more than raw capacity.

Multiple compressors allow:

• Load sharing

• Efficient part-load operation

• Backup capability

• Easier maintenance scheduling

This approach often improves reliability and reduces risk.

Sizing Mistakes Are Expensive to Fix After the Fact

Replacing or resizing a compressor after installation is costly and disruptive.

That’s why proper evaluation upfront is critical:

• Measure real demand

• Understand load patterns

• Factor in storage and controls

• Plan for realistic growth

Good sizing decisions prevent years of unnecessary expense.

The Best Compressor Size Comes From System Data

There’s no universal “right size” for a compressor.

The right size depends on:

• Actual CFM usage

• Demand variability

• Operating pressure

• Storage capacity

• Control strategy

• Duty cycle

Data-driven sizing delivers better reliability, lower energy cost, and longer equipment life.

Compressor Sizing Is About Balance, Not Guesswork

A properly sized compressor runs cooler, lasts longer, and costs less to operate. Oversized and undersized systems both create problems that slowly erode reliability and efficiency.

If you’re unsure whether your compressor is correctly sized — or you’re planning changes to production — a system evaluation can prevent costly mistakes and ensure long-term performance.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing compressor sizing evaluations, system design, upgrades, and full compressed air support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

How to Detect Inefficiencies in Your Compressed Air Controls

Compressed air controls don’t usually fail in obvious ways. When they’re inefficient, the system still runs, tools still work, and production continues — but energy costs climb, compressors wear faster, and pressure stability slowly gets worse. Many facilities live with control problems for years without realizing how much money they’re leaving on the table.

At Industrial Air Services, we routinely find control inefficiencies in systems across Nashville, Knoxville, and Chattanooga, especially in facilities that have grown or changed over time. Here’s how to recognize when your compressed air controls aren’t doing their job.

Your Compressor Runs Even When Demand Is Low

One of the clearest signs of poor control is a compressor that runs unnecessarily.

Watch for:

• Compressors running during breaks or off-shifts

• Long unloaded run times

• Machines staying powered when air demand drops

This usually means the system lacks proper sequencing, demand-based control, or modern automation.

Multiple Compressors Are Fighting Each Other

In multi-compressor systems, poor controls can cause machines to work against one another.

Common symptoms include:

• Two compressors loading at the same time when one could handle demand

• Compressors rapidly loading and unloading

• Uneven run hours between machines

• Inconsistent system pressure

When compressors “fight,” energy use skyrockets and wear accelerates.

Pressure Fluctuates More Than It Should

Good controls maintain stable pressure. Bad controls react too late.

If you see:

• Pressure swings during normal operation

• Operators adjusting regulators frequently

• Pressure setpoints creeping higher over time

…it’s often a control logic issue, not a compressor problem.

You’ve Raised System Pressure to Compensate

Increasing pressure is one of the most common ways facilities unknowingly mask control inefficiencies.

Higher pressure is often used to:

• Overcome slow response times

• Compensate for poor sequencing

• Hide storage or piping problems

This wastes energy and shortens equipment life without fixing the root cause.

Compressors Short-Cycle or Switch Modes Frequently

Short-cycling is hard on motors, starters, and controls.

It’s commonly caused by:

• Poor load/unload timing

• Inadequate storage

• Improper control settings

• Mismatched compressors

Controls should smooth operation — not create constant transitions.

Older Controls Lack Visibility

Many older control panels provide little insight into how the system actually runs.

Without visibility into:

• Load vs. unload time

• Run hours

• Pressure trends

• Alarm history

…it’s impossible to optimize performance or identify inefficiencies early.

Your System Has Grown, But Controls Haven’t

Production changes often outpace control upgrades.

This happens when:

• New equipment is added

• Shifts increase or change

• Demand becomes more variable

• A second compressor is installed without proper sequencing

Controls designed for yesterday’s system won’t manage today’s demand efficiently.

Energy Costs Rise Without a Clear Explanation

When controls are inefficient:

• Compressors run longer than necessary

• Motors draw more power

• Peak demand charges increase

If your energy bill keeps climbing but production hasn’t changed, control inefficiencies are a prime suspect.

No Central Control or System Coordination

In many facilities, each compressor operates independently.

This leads to:

• Redundant operation

• Poor load sharing

• Inconsistent pressure

• Higher wear across all machines

Centralized control allows the system to behave like a single, coordinated unit instead of separate machines guessing what to do.

Alarms and Faults Occur More Frequently

Poor control logic can push compressors outside their ideal operating range.

This increases:

• High-temperature alarms

• Pressure-related shutdowns

• Electrical faults

• Emergency service calls

Better controls keep compressors operating within safe, efficient limits.

Modern Controls Often Deliver the Fastest ROI

Upgrading controls doesn’t always require new compressors.

Modern control solutions can:

• Improve sequencing

• Reduce energy waste

• Stabilize pressure

• Extend equipment life

• Lower operating costs

In many cases, control upgrades pay for themselves faster than major equipment replacements.

Compressed Air Controls Should Work Quietly in the Background

When controls are doing their job, you barely notice them. Pressure stays stable, compressors run smoothly, and energy costs stay predictable. When controls are inefficient, the system slowly becomes more expensive and less reliable.

If you suspect your compressed air controls aren’t optimized, a system evaluation can quickly identify where improvements will have the biggest impact.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing compressed air control evaluations, system optimization, and efficiency upgrades.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

When to Upgrade to a Variable Speed Drive (VSD) Compressor

Variable Speed Drive (VSD) compressors are everywhere now. They’re marketed as the ultimate energy-saving solution, and in the right application, they truly are. But a VSD isn’t automatically the best choice for every facility. The key is understanding how your air demand behaves and whether a VSD fits your operation — not just chasing the latest technology.

At Industrial Air Services, we work with facilities across Nashville, Knoxville, and Chattanooga that are considering a VSD upgrade. Some see immediate savings. Others are better served with different solutions. Here’s how to tell if a VSD compressor is the right move for your system.

1. Your Air Demand Fluctuates Throughout the Day

VSD compressors shine when demand changes.

If your facility:

• Has peak production times

• Experiences frequent start/stop cycles

• Runs different equipment at different times

• Has shifts with varying air usage

…a VSD can adjust output in real time to match demand instead of running full throttle all day.

Fixed-speed compressors can’t do this efficiently.

2. Your Compressor Spends a Lot of Time Unloaded

An unloaded compressor still consumes energy — often 20–40% of full load power.

If your compressor:

• Runs unloaded frequently

• Cycles between load and unload constantly

• Stays powered even when air demand is low

…you’re paying for air you’re not using.

A VSD reduces speed during low demand instead of wasting power in unload mode.

3. You’re Trying to Reduce Energy Costs Without Cutting Production

Energy savings are one of the biggest reasons facilities move to VSD technology.

A properly applied VSD compressor can:

• Reduce energy consumption by 20–35%

• Lower peak demand charges

• Stabilize pressure without overcompensating

• Reduce heat generation

If electricity costs are climbing and production can’t slow down, a VSD may be the right answer.

4. Pressure Stability Is Critical to Your Process

Some processes are sensitive to pressure fluctuations.

VSD compressors provide:

• Tight pressure control

• Smooth ramp-up and ramp-down

• Consistent air delivery

This benefits:

• CNC equipment

• Packaging lines

• Robotics

• Painting and coating

• Food and beverage processes

Stable pressure improves product quality and reduces machine errors.

5. You’re Currently Running at Higher PSI Than Needed

Many facilities increase system pressure to compensate for pressure drops.

A VSD can:

• Maintain stable pressure at a lower setpoint

• Reduce artificial over-pressurization

• Cut energy waste from excess PSI

Lower pressure plus smarter control equals real savings.

6. Your Existing Compressor Is Near End of Life

If your current compressor is:

• Experiencing frequent breakdowns

• Running hot

• Losing efficiency

• Costing more to maintain

…it may be the right time to upgrade rather than repair.

Installing a VSD during a planned replacement is far more cost-effective than waiting for a failure.

7. You Have One Main Compressor Handling the Entire Load

Single-compressor systems are common — and risky.

A VSD can:

• Serve as a trim compressor alongside an existing unit

• Handle variable demand while a fixed-speed unit carries the base load

• Improve overall system efficiency

This hybrid setup often delivers the best return on investment.

8. You Want to Reduce Wear and Extend Equipment Life

VSD compressors:

• Start more smoothly

• Reduce mechanical shock

• Run cooler at partial load

• Cycle less aggressively

This extends the life of:

• Motors

• Bearings

• Air ends

• Electrical components

Less stress means fewer failures.

9. When a VSD May Not Be the Best Option

A VSD may not be ideal if:

• Your air demand is constant and steady

• The compressor runs fully loaded most of the time

• The environment is extremely dirty or hot without proper ventilation

• Budget constraints outweigh energy savings

In these cases, a well-sized fixed-speed compressor with proper storage may be the better choice.

10. The Best VSD Upgrade Starts With a System Evaluation

Before upgrading, it’s important to look at:

• Actual CFM demand

• Load/unload patterns

• Pressure drop

• Storage capacity

• Leak levels

• Operating hours

A VSD delivers the biggest savings when it’s sized and applied correctly within the entire system — not installed in isolation.

A VSD Compressor Is a Powerful Tool — When Used in the Right System

Variable speed technology can dramatically improve efficiency, lower energy costs, and stabilize performance — but only when it matches how your facility actually uses air.

If you’re considering a VSD upgrade, we can evaluate your system, calculate potential savings, and help you decide whether a VSD is the right investment for your operation.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, offering VSD compressor evaluations, system design, installations, and full compressed air support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

Why Moisture Problems Get Worse During Seasonal Transitions

If it feels like moisture problems show up out of nowhere during spring and fall, you’re not imagining it. Seasonal transitions are one of the most challenging times for compressed air systems. Temperatures swing, humidity spikes, and systems that ran fine for months suddenly start sending water into filters, tools, and production equipment.

At Industrial Air Services, we see a sharp increase in moisture-related service calls across Nashville, Knoxville, and Chattanooga during seasonal changeovers. Understanding why this happens makes it much easier to stay ahead of the problem.

1. Temperature Swings Create Sudden Condensation

Compressed air always contains water vapor.
When temperatures change quickly, that vapor turns into liquid.

During seasonal transitions:

• Warm, humid air cools rapidly overnight

• Cold air warms quickly during the day

• Pipes and tanks change temperature constantly

Each temperature swing creates new condensation inside the system, even if nothing else has changed.

2. Humidity Levels Spike in Spring and Fall

Tennessee’s humidity doesn’t gradually increase or decrease — it jumps.

Higher humidity means:

• More water enters the compressor

• Dryers must remove a larger moisture load

• Drains cycle more often

• Filters saturate faster

A dryer that handled summer conditions may struggle when humidity shifts unexpectedly in early fall or spring.

3. Dryers Are Often Sized for “Normal” Conditions

Many dryers are sized just large enough to handle average operating conditions. Seasonal transitions push them beyond that comfort zone.

When dryers are overloaded:

• Dew point rises

• Moisture passes downstream

• Water collects in piping

• Rust accelerates

This is why moisture problems often appear suddenly — the dryer hasn’t failed, it’s just overwhelmed.

4. Condensate Drains Fail During Seasonal Changeovers

Drains are one of the most common failure points.

During seasonal transitions:

• Sludge thickens

• Rust flakes break loose

• Oil carryover increases

• Temperature changes affect drain timing

A drain that worked “well enough” in summer may stick or clog when conditions change, allowing water to back up into the system.

5. Cold Piping Surfaces Encourage Water Drop-Out

When warm compressed air hits cooler piping, moisture drops out immediately.

This is especially common:

• Early mornings in spring and fall

• In uninsulated areas

• Near exterior walls

• In older buildings

Water forms faster than the system can remove it, leading to puddling in low spots and drop legs.

6. Systems With Poor Pipe Slope Suffer the Most

Seasonal moisture exposes piping design flaws.

If piping:

• Is level instead of sloped

• Has no drop legs

• Lacks drain points

• Has corrosion pockets

Water has nowhere to go — except into tools and equipment.

7. Wet Tanks Fill Faster Than Expected

During seasonal transitions, receiver tanks often accumulate water much faster.

If tanks aren’t drained regularly:

• Water carries downstream

• Dryers become overloaded

• Filters saturate

• Rust develops internally

Many facilities are surprised by how much water shows up during these periods.

8. Reduced Airflow Makes Moisture Removal Harder

Clogged filters, dirty coolers, or restricted piping reduce airflow and increase dwell time inside the system.

This causes:

• More condensation

• Poor dryer performance

• Higher dew point

Moisture problems often worsen when airflow is already compromised.

9. Production Changes Can Make Moisture Seem “Sudden”

Seasonal production shifts often coincide with weather changes.

Lower air usage can:

• Reduce dryer efficiency

• Cause refrigerated dryers to ice

• Increase moisture carryover

When load drops, dryers don’t always behave as expected.

10. Seasonal Moisture Problems Are Predictable — and Preventable

The good news is that moisture issues during seasonal transitions are not random.

They can be managed by:

• Checking and cleaning drains before the season changes

• Verifying dryer performance and dew point

• Draining receiver tanks more frequently

• Inspecting filters early

• Improving ventilation

• Insulating exposed piping

• Addressing low points in piping

A little preparation prevents a lot of headaches.

Seasonal Moisture Problems Don’t Mean Your System Is Broken

They mean your system is reacting to changing conditions. Once moisture is controlled at the source — through proper drying, drainage, and airflow — seasonal transitions stop being a problem.

If you’re dealing with water in your air lines every spring or fall, we can evaluate your system and recommend practical fixes that keep moisture under control year-round.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing moisture control solutions, dryer service, drain repairs, and full compressed air system support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

The Role of Proper Storage in Compressed Air System Efficiency

Air receiver tanks don’t usually get much attention. They sit quietly in the corner, doing their job without alarms or flashy controls. But when a compressed air system struggles with pressure swings, short-cycling, moisture problems, or high energy costs, the root cause is often simple: there isn’t enough air storage, or it’s not placed correctly.

At Industrial Air Services, we see storage issues in facilities across Nashville, Knoxville, and Chattanooga every week. Adding or correcting air storage is one of the most cost-effective upgrades you can make — and one of the fastest ways to improve efficiency without replacing your compressor.

Here’s why storage matters so much.

1. Air Storage Stabilizes System Pressure

Compressed air demand is rarely steady. Tools cycle, machines pulse, valves open and close — all of it happens in bursts.

Without adequate storage:

• Pressure drops suddenly

• Tools feel weak

• Operators complain

• The compressor reacts too late

A properly sized receiver tank absorbs those demand spikes and delivers air instantly, keeping pressure stable throughout the system.

2. Storage Reduces Compressor Short-Cycling

Short-cycling is hard on compressors and expensive to ignore.

When storage is undersized:

• Pressure rises and falls too quickly

• The compressor starts and stops repeatedly

• Motors and starters wear out faster

• Energy consumption increases

More storage means fewer starts, longer run cycles, and smoother operation — especially on piston and fixed-speed rotary screw compressors.

3. Receiver Tanks Help Lower Energy Costs

Every time a compressor starts, it draws a surge of power.
Excessive cycling wastes energy.

With proper storage:

• The compressor runs longer, more efficient cycles

• Load/unload behavior improves

• Peak demand charges can be reduced

• Pressure doesn’t need to be artificially increased

Many facilities see measurable energy savings simply by adding a tank.

4. Storage Improves Dryer Performance

Dryers work best when airflow and temperature are stable.

A wet tank before the dryer allows:

• Hot compressed air to slow down

• Moisture to condense out naturally

• Drains to remove water before it hits the dryer

This reduces dryer load and improves dew point performance — a major benefit in Tennessee’s humid climate.

5. Dry Storage After the Dryer Supports Clean Air Delivery

A dry tank after the dryer provides:

• Clean, dry air storage

• Stable pressure at the header

• Protection during peak demand

• Better tool and machine performance

This is especially important for processes sensitive to moisture or pressure fluctuations.

6. Storage Helps Mask Short Bursts — Not System Deficiencies

Receiver tanks are great for handling short bursts of demand, such as:

• Tool startup

• CNC tool changes

• Actuated valves

• Sanding or blasting cycles

However, storage should support the compressor — not replace it.
If your compressor can’t keep up long-term, storage alone won’t fix it. But when sized correctly, it makes the whole system work smarter.

7. Tank Placement Matters as Much as Tank Size

A tank placed in the wrong location won’t help much.

Best practices include:

• Wet tank close to the compressor

• Dry tank near the main header

• Tanks installed where drains are easy to access

• Minimal restriction between tank and system

Good placement ensures the stored air is actually usable where it’s needed.

8. Storage Helps Manage Leaks and Pressure Drop

Leaks are inevitable, but storage helps soften their impact.

With adequate storage:

• Pressure doesn’t collapse instantly when a leak occurs

• The compressor doesn’t overreact

• Operators notice problems sooner instead of compensating with higher PSI

This makes leak detection and system control easier.

9. More Storage Means More Room for Growth

As facilities grow, air demand increases. Storage provides a buffer that:

• Supports additional tools

• Allows time to plan compressor upgrades

• Reduces stress during expansion phases

Many facilities regret not adding storage sooner.

10. Air Storage Is One of the Cheapest Efficiency Upgrades You Can Make

Compared to compressors, dryers, or piping upgrades, receiver tanks are relatively inexpensive — and the return on investment is often immediate.

Proper storage:

• Improves efficiency

• Reduces wear

• Lowers energy cost

• Stabilizes pressure

• Improves air quality

• Extends compressor life

It’s one of the smartest first steps in system optimization.

A Well-Stored Air System Runs Smoother, Cooler, and Cheaper

If your compressor cycles too often, pressure fluctuates, or energy costs keep climbing, your system may simply need more — or better-placed — air storage.

We can evaluate your current setup, determine the right storage strategy, and install tanks that immediately improve performance.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, offering air receiver tank sizing, installation, system optimization, and full compressed air support.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com

How to Tell If Your Air Compressor Is Wasting Energy

Compressed air is one of the most expensive utilities in a facility, yet it’s also one of the easiest places for energy waste to hide. Unlike lighting or HVAC, compressed air inefficiencies aren’t always obvious. The system still runs, tools still work, and production keeps moving — but behind the scenes, your compressor may be burning far more electricity than necessary.

At Industrial Air Services, we help facilities across Nashville, Knoxville, and Chattanooga identify where energy is being lost in their air systems and how to correct it. Here are the most common signs your compressor is wasting energy — and what they usually mean.

1. Your Compressor Runs Constantly, Even During Light Production

A compressor that rarely shuts off is a major red flag.

Common causes include:

• Air leaks

• Undersized storage

• Pressure set too high

• Demand exceeding system capacity

• Poor controls or outdated sequencing

Even small leaks can force a compressor to run nonstop, quietly driving up your electric bill.

2. Your Energy Bills Keep Rising Without a Production Increase

If production hasn’t changed but your power bill has, compressed air is often the culprit.

Energy waste shows up as:

• Higher kWh usage

• Increased peak demand charges

• Longer compressor run times

• Motors pulling more amps

Compressed air inefficiencies compound quickly — especially during hot, humid Tennessee summers.

3. You’ve Raised System Pressure to “Fix” Performance Issues

Increasing PSI is one of the most expensive band-aids in compressed air systems.

For every 2 PSI increase, energy use rises by roughly 1%.

If your pressure has crept up over time, it often means:

• Leaks haven’t been fixed

• Piping is undersized

• Filters are clogged

• Storage is inadequate

Higher pressure doesn’t fix problems — it just hides them while wasting energy.

4. Your Compressor Short-Cycles or Rapidly Loads and Unloads

Excessive cycling wastes energy and wears out components.

Short-cycling is usually caused by:

• Too little air storage

• Sudden demand spikes

• Leaks

• Poor control logic

Each start-up pulls a surge of power, which adds up fast over time.

5. Filters Are Plugging Faster Than Normal

Dirty filters increase pressure drop, forcing the compressor to work harder.

When filters clog quickly, it often points to:

• Moisture overload

• Oil carryover

• Rust from piping

• Poor dryer performance

The compressor compensates by consuming more energy to maintain pressure.

6. Your Compressor Runs Hotter Than It Used To

Heat and inefficiency go hand in hand.

A compressor that runs hot is usually:

• Working too hard

• Starved for airflow

• Poorly ventilated

• Running at excessive pressure

Higher temperatures reduce efficiency and shorten oil and component life.

7. You Hear Air Leaks but Haven’t Addressed Them

Leaks are one of the largest sources of wasted compressed air.

A single ⅛-inch leak can cost thousands of dollars per year in energy alone.

Leaks commonly occur at:

• Quick-connect fittings

• Hoses and reels

• Regulators

• Valves

• Old piping joints

If you can hear leaks, you’re definitely paying for them.

8. Your Compressor Is Older and Lacks Modern Controls

Older fixed-speed compressors run at full output whether you need the air or not.

Without modern controls:

• The compressor wastes air during unload cycles

• Power consumption stays high during low demand

• Energy savings opportunities are missed

Newer control strategies and VSD technology dramatically reduce wasted energy.

9. You Don’t Have Visibility Into Run Time or Power Draw

If you’re not tracking:

• Hours run

• Load vs. unload time

• Amp draw

• Pressure trends

…it’s almost impossible to know how much energy is being wasted.

Monitoring reveals inefficiencies that otherwise go unnoticed.

10. Your System Has Never Been Audited

Many facilities operate for years without a compressed air audit.

An audit identifies:

• Leaks

• Pressure drop

• Oversized or undersized equipment

• Storage issues

• Control inefficiencies

Most audits uncover enough waste to pay for themselves quickly.

Energy Waste in Compressed Air Is Common — but Fixable

Compressed air systems naturally drift toward inefficiency over time. Leaks develop, demand grows, and settings get adjusted without addressing root causes. The good news is that most energy waste can be corrected with targeted improvements — often without replacing the compressor.

If you suspect your system is wasting energy, we can evaluate it and show you exactly where savings are hiding.

Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing energy audits, leak detection, system optimization, and full compressed air service.

📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com