What is compressed air leak detection?

Compressed air leak mapping is a method in which leaks in an industrial compressed air system are located using an ultrasonic or acoustic camera without stopping production.

How we serve

• We map leaks
• You will receive a report, prioritization and savings estimate
• Agreeing on repair liability
• Energy consumption is reduced immediately
• Available for follow-up for next year
• We can draw up an annual contract for leak detection
• You can also combine the service with compressed air quality assurance (compressed air humidity and residual oil content).

Figure 1. Compressed air leak detection on a saw

How much do compressed air leaks cost the industry?

Key indicators of compressed air leaks in industry

In the engineering and metalworking industries, compressed air leaks cause significant energy loss. Leak surveys show that a typical production facility has dozens of leaks in the compressed air system, which increases energy consumption and operating costs. In an industrial facility, compressed air leaks can cause energy costs of €2,000–10,000 per year.

The data below is based on SmartAir research on the subject, with the latest update version being February 23, 2026. Source: SmartAir And Energy Oy leak descriptions.

What does compressed air leak detection mean?

Explanation: Compressed air leak mapping is a method in which leaks in a compressed air system are located using an ultrasonic or acoustic measuring device without stopping production.

• leak location
• leak rating
• reportage
• a clear energy saving estimate and how it will be achieved
• correction suggestions
• also compressed air safety observations

How to conduct a compressed air leak survey - and turn costs into savings

If there are no compressed air leaks at the site, we will tell you honestly.
The minimum cost of a leak survey is 290 EUR/vat0%.

Note. Repairs are carried out either by the customer or by SmartAir, as agreed separately. Our service is available with an annual contract, which can be combined with compressed air quality assurance.

We turn compressed air leaks from expenses into savings - even in one week.

A single leak can cost up to €600 per year. In this case, that meant 5,800 kWh of energy loss.

Leakage point	Energy cost / year
1mm hole	~300 €
3mm hole	~2000 €
5mm hole	~6000 €

Figure 3. The leaking compressed air hose in the picture causes 5,800 kWh of energy loss per year.

Case study: Sinituote Oy - Kokemäki compressed air leaks and energy survey

The survey found a total of 40 compressed air leaks, which caused significant energy loss. The leaks were mainly located in joints, hoses and compressed air tools.

Key results of the survey

• Average compressed air consumption: 4.4 m³/min
• Compressed air loss due to leaks: 0.52 m³/min
• Leakage share of consumption: 12%
• Detected leaks: 40 pcs

Figure 2. Sinituote's factory in Kokemäki. Archive photo. Photo: Sinituote

Energy impact Energy loss due to leaks: 21,912 kWh per year.
Compressed air energy consumption in relation to electricity consumption: 8.8%.

Economic & Environmental Impact Estimated cost: €2,191 per year.
CO₂ emissions caused by leaks: 1534 kg per year.

Results of the compressed air leak surveys carried out

We have carried out several dozen compressed air leak surveys for various industrial sectors in Finland in 2023–2025. The surveys have been conducted in production facilities where compressed air is used, for example, in production machines, automation and compressed air tools. Based on the surveys, compressed air leaks are very common in industry, and repairing them can bring significant energy savings.

Average results from surveys carried out based on completed compressed air leak surveys:

• average energy savings: €3,795 per year
• average payback period (ROI): 8.4 months
• typical savings: €2,000–8,000 per year

In several locations, the savings have been greater than this. At the largest single location, repairing compressed air leaks enabled more than €12,000 in annual energy savings. The payback period is based on the cost of the compressed air leak detection service in relation to the energy cost caused by the leaks, which the customer fixes after the detection.

Results of the compressed air leak surveys carried out

Below are examples of compressed air leak surveys carried out in various industries in Finland.

What do the results tell us about compressed air leaks?

Based on the surveys carried out, compressed air leaks can cause a significant portion of the energy consumption of a compressed air system. Typically, there are several dozen leaks in one production facility, and the energy loss caused by them increases rapidly if the leaks are not repaired.

Compressed air leak mapping helps identify leak locations quickly and prioritize repairs based on their energy impact. In many locations, simply fixing the largest leaks has been enough for the mapping to pay for itself in less than a year.

Calculation basics

The savings shown in the table are based on calculations using Fluke LeakQ software, which uses:

• operating hours reported by the customer
• the total electricity price (energy + transmission) reported by the customer

The average electricity price used in the calculation is €0.10/kWh. ROI describes the payback period of the compressed air leak detection service in relation to the energy cost caused by the leaks, which the customer repairs after the detection. The calculation does not include possible leak repair costs.

The most common compressed air leaks

Compressed air leaks most often occur in mechanical joints and compressed air components. The most common leak locations in leak surveys are:

• quick connectors
• threaded connections
• hose connections
• compressed air guns
• valves
• cylinders
• filter and regulator units
• worn or hardened compressed air hoses
• compressed air connections for machines
• trunk line connections

Especially in production facilities, leaks often occur in the connections of machines and pneumatic tools, where connectors are frequently disconnected and connected.

Can you afford not to perform a compressed air leak survey?

Compressed air leak detection is one of the most effective ways to improve industrial energy efficiency and realize financial savings without risk or customer time.

The key benefits are:

• reducing energy costs
• reducing the load on compressors
• accurate information about the condition and efficiency of the compressed air network
• freeing up compressed air system capacity
• improving the reliability of production equipment
• Precise maintenance that increases production reliability and reduces costs
• reducing carbon dioxide emissions
• improving energy efficiency in production
• especially ISO50001 certification and energy efficiency agreements for companies as part of continuous improvement

Leak detection often pays for itself in less than a year when the largest leaks are repaired.

Compressed air leak repair by SmartAir

Most causes of compressed air leaks are relatively inexpensive to repair. They often involve replacing a connector or hose, which means the repair time is short.

Low repair costs mean a short payback period for the item, which after renovation produces clear savings, and it will no longer be an expense item in the future.

As a subscriber, you can repair compressed air leaks independently or you can request a repair service from us.

The key benefits are:

• the customer does not need to spend resources on mapping or renovation
• An estimate of renovation costs can be agreed upon for leak mapping
• By determining the renovation costs, we can obtain a payback period (ROI) for the investment.
• order of leak repairs according to the reported priority order
• leak repair according to an agreed schedule

Annual leak detection contract – Compressed air network maintenance outsourcing

With the agreement, the entire leak survey and any related repairs are automated, and a separate order for the next visit is not required.

The contract also defines the lowest cost for leak detection, if the number of compressed air leaks and the resulting loss is low - this way you don't pay for nothing.

• a clear operating model with agreed responsibilities
• Individual pricing by agreement
• A clear report shows the status of the compressed air network, the need for repairs with suggestions, and the resulting cost.

The service can be combined with compressed air network services

Read more about compressed air network services

• Transferring responsibility for maintaining the entire compressed air network in exchange for an annual fee
• The scope is agreed upon individually for each client.

The service can also be combined with services related to ensuring compressed air quality.

Read more about compressed air quality measurement

• moisture content of compressed air
• residual oil content of compressed air
• A clear report shows the quality of the compressed air and how it meets the customer's needs
• we report the need for renovation with suggestions and the resulting cost

Pricing

Our annual contract service, which includes leak detection, compressed air network maintenance, and compressed air quality assurance, performed once a year.

The price is affected by the location of the site, the productive area of the site, and the amount of compressed air used. Price starting at 890 EUR/year (alv0%)

Frequently Asked Questions (FAQ)

Compressed air leak survey in Finland

We offer compressed air leak surveys for example:

• Turku
• Helsinki (metropolitan area)
• Tampere
• Oulu
• Jyvaskyla
• Lappeenranta
• everywhere in Finland