5 Common Compressed Air Problems in Industrial Settings and How Automation Solves Them

1. Pressure Drops Across the System

A pressure drop is one of the most widespread and costly issues in compressed air systems. It occurs when air loses pressure as it moves through pipes, filters, dryers, or other system components. If the pressure at the point of use is too low, equipment performance drops, and your operations suffer.

Causes of pressure drops include:

• Undersized or poorly designed piping
• Dirty or clogged filters
• Excessive moisture or oil in the air
• Long distribution lines with sharp bends or leaks

How automation solves it:
Automated compressed air systems equipped with pressure sensors and real-time monitoring software can identify pressure drops immediately. Instead of relying on manual checks, your system can send alerts when pressure falls outside of the optimal range. At Decode Automation, we implement smart pressure monitoring systems that help you pinpoint where pressure loss occurs and take corrective action before it causes downtime.

2. Undetected Air Leaks

Air leaks are silent profit killers. According to the Compressed Air and Gas Institute (CAGI), a single 3mm leak can cost thousands of dollars a year in wasted energy. Now imagine if your facility has 20 or more such leaks, it adds up fast.

Signs of a leaking compressed air system include:

• Unexplained energy usage increases
• Compressor running constantly even during idle periods
• Low pressure at end-use points
• Audible hissing around fittings, couplings or hoses

How automation solves it:
Through the use of smart sensors and flow meters, an automated system can detect anomalies in air consumption and flag unusual patterns. Decode Automation integrates real-time data logging to isolate where leaks are occurring, making your maintenance process faster and more accurate. Combined with an ongoing leak detection and repair program, you can drastically reduce unnecessary energy loss.

3. Moisture and Contaminants in the Air

Compressed air isn’t just air, it often contains water vapour, oil, and particles that can damage tools and contaminate products. This is especially dangerous in industries like food and beverage, pharmaceuticals, and electronics, where clean, dry air is essential.

Problems caused by poor air quality include:

• Rust in piping and tools
• Product contamination
• Premature wear on equipment
• Clogged nozzles or valves

How automation solves it:
By automating your air dryer system and implementing smart dew point monitoring, you can ensure that your air stays clean and dry. Decode Automation uses advanced compressed air treatment solutions, including inline monitoring that adjusts filtration in real-time. When air quality drops, your system will notify maintenance teams automatically, preventing expensive contamination events.

4. Inefficient Compressor Operation

Running compressors at full tilt when it’s not necessary is one of the most common ways companies lose money on compressed air. Many facilities still rely on manual control or outdated pressure-based triggers, leading to inefficient cycling and excess wear.

Signs of inefficiency include:

• Compressors running unloaded for long periods
• Operating multiple compressors when only one is needed
• High energy bills for low output
• Frequent breakdowns or overheating

How automation solves it:
Decode Automation offers smart compressor controls that use demand-based logic. By monitoring your actual compressed air usage, the system can adjust compressor activity, accordingly, starting or stopping machines only when needed. Our solutions also include predictive maintenance scheduling, so you’re not relying on calendar-based servicing that may be too early, or too late.

The result is lower power consumption, extended compressor life, and reduced maintenance costs.

5. Lack of Real-Time Visibility and Control

Perhaps the biggest problem with most industrial compressed air systems is that they operate blindly. Without access to real-time data, facility managers often find out about a problem only after it causes downtime or product quality issues.

Consequences of poor system visibility include:

• Delayed responses to system failures
• Inability to optimise air usage
• Missed opportunities for energy savings
• Difficulty in scheduling proactive maintenance

How automation solves it:
Decode Automation provides integrated system dashboards that give you full visibility over your compressed air network. You can monitor flow rates, pressure levels, energy consumption, and maintenance status, all from one location. Many of our clients benefit from remote monitoring, allowing them to access system data from mobile devices or desktops at any time.

We also integrate with platforms like Airtx, which offer intelligent compressed air control valves and sensors for even greater precision and automation.

Bonus: The Hidden Cost of Doing Nothing

If you’re dealing with compressed air issues and haven’t yet invested in automation, the real question becomes, how much are you losing each month?

Without smart compressed air solutions in place, you’re likely facing:

• Up to 30 percent of energy loss due to leaks and inefficiency
• Unplanned downtime costing thousands in lost output
• Shortened equipment lifespan due to reactive maintenance
• Lower product quality or compliance issues

By automating your compressed air systems, you not only gain back control but also create a foundation for sustainable, efficient, and scalable industrial operations.

 

How Decode Automation Can Help

Decode Automation is a leader in industrial automation solutions tailored to compressed air systems. With experience across manufacturing, processing, logistics, and more, we understand the challenges faced by Australian businesses.

Our team designs and implements customised automation systems that include:

• Smart sensors and monitoring devices
• Air flow and pressure control systems
• Remote system dashboards
• Leak detection integration
• Predictive maintenance tools

And because we partner with advanced technology providers like Airtx, we’re able to offer the latest innovations in smart pneumatics and compressed air automation.