Compressed Air Leak Cost
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The compressor keeps loading when production is quiet, and nobody owns the hiss. Turn leak or unload share into wasted units and rupees before the next air audit.
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The formula we use
wasteKWh = kW * hours * share/100
cost = wasteKWh * rate
- Leak share should come from audit measurement if possible.
- Does not model pressure setpoint, compressor sequencing or demand charge effects.
- Fixing leaks can change compressor cycling, so verify after repair.
Typical numbers
Reference figures to sanity-check your inputs. Your own bill and equipment data always win.
BEE's MSME guideline gives single-stage screw compressor specific power at 0.14 to 0.25 kW per cfm.
Source: BEE MSME Guidelines, 2019
BillTrends' compressor module uses 0.20 kW per cfm as the safe screening default.
Source: BillTrends default model
A 10% leak on a 100 cfm compressor at 0.20 kW/cfm wastes 2 kW while the compressor is loaded.
Source: BillTrends default model
BillTrends' pressure-band screening default is 7% compressor kWh per bar of avoidable pressure reduction.
Source: BillTrends default model
BEE's MSME compressor table covers FAD values from 20 to 7,000 cfm across common compressor types.
Source: BEE MSME Guidelines, 2019
Common questions
How do I know the leak or unload share?
Use an audit measurement, compressor controller data, no-production run test or logged loading pattern. The example must be edited.
Is compressed air really expensive?
Yes, because electricity is converted into air and then often lost through leaks, pressure drops or misuse.
Does fixing leaks reduce demand too?
Sometimes. If leaks keep a compressor loaded during peaks, reducing them can also reduce maximum demand.