Compressed air is often called the plant’s “fourth utility”. It is also one of the most expensive: for every 100 kWh a compressor uses, only around 10 to 15 kWh end up as useful work. The rest is lost as heat… and through leaks. In many Moroccan industrial sites we visit, leaks alone account for 20 to 30% of the air produced.
What does a leak really cost?
A leak is silent in a busy workshop, but it runs 24/7 as long as the network is pressurised. Its cost depends on the hole diameter, the pressure and the operating hours.
Rough figures at 7 bar
- 1 mm hole: around 1,200 kWh lost per year
- 3 mm hole: around 11,000 kWh lost per year
- 5 mm hole: around 30,000 kWh lost per year
These figures are indicative, for continuous operation. Multiplied by the price per kWh and the number of leaks in a network, they explain why leak hunting is often the most profitable investment in a compressor room.
Where do leaks hide?
At the points of use
Worn quick couplings, cracked hoses, blow guns left open, poorly maintained pneumatic tools: this is where most leaks are found.
On the network and in the compressor room
Filter and regulator seals, valves, flanges, condensate drains stuck open: these leaks go unnoticed because they are in areas people rarely visit.
The Deutsche TechnicAir method
1. Measure
We measure the flow consumed while production is stopped. All air produced at that moment goes into leaks: this is the baseline.
2. Locate
Using an ultrasonic detector, our technicians locate every leak, even in a noisy workshop. Each point is tagged, photographed, costed and prioritised.
3. Repair and verify
After repairs, a new measurement confirms the real saving in kWh and dirhams. We recommend repeating the campaign every year.
Going further: matching production to demand
Once leaks are fixed, air demand drops. It is the right moment to review the station: a variable-speed BOGE compressor and an airtelligence provis 3 central control avoid producing unnecessary air and cut the bill further.
Frequently asked questions
How long does a leak audit take?
For an average site, one to two days on site are enough, followed by a detailed report.
Does production need to stop?
No. The baseline is ideally measured during a stoppage (weekend, break), but ultrasonic detection is done during normal operation.
A question about your installation?
Our engineers assess your needs and propose the right BOGE solution.