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Air End
Repair

Compressed
Air Leak Audits

System
Design

Technical
Service

AIRTILITY
program

Compressed
Air Audit Services

Remote
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Compressed Air Leak Audits

Massachusetts Compressed Air Optimization

Ultrasonic Leak Detection for Massachusetts Industrial Facilities

Compressed air leaks are one of the largest sources of wasted energy in industrial facilities throughout Massachusetts. COMAIRCO provides professional compressed air leak audits and ultrasonic leak detection services that help manufacturers reduce operating costs, improve system reliability, and optimize compressed air system performance. Our team supports facilities in Boston, Worcester, Springfield, Lowell, Cambridge, Brockton, New Bedford, Quincy, and surrounding industrial communities across the Commonwealth.

Air Leak Audits

Compressed Air Leak Audits for Northeast Manufacturers

From New York and Pennsylvania to New Jersey, New Hampshire, Massachusetts, Maine, and West Virginia, industrial facilities rely on compressed air for production, automation, packaging, assembly, and process applications. Even a well-maintained compressed air system can develop leaks that increase operating costs and reduce system efficiency. COMAIRCO helps facilities throughout the Northeast identify and prioritize leak repairs using advanced ultrasonic leak detection technology and compressed air leak management best practices.

Industries We Serve

  • Manufacturing
  • Food & Beverage
  • Pharmaceutical
  • Plastics
  • Automotive
  • Aerospace
  • Chemical Processing
  • Metal Fabrication
  • Electronics
  • Wastewater Treatment
  • Pulp & Paper
  • Energy & Utilities
COMAIRCO technician wearing a hard hat, safety glasses, hearing protection, and a high-visibility safety vest using an ultrasonic leak detector in an industrial compressed air system.Image generated with Microsoft Copilot for COMAIRCO.

Why Perform a Compressed Air Leak Audit?

Compressed air systems naturally develop leaks over time at fittings, hoses, couplings, valves, regulators, filters, and production equipment. Without a structured leak management program, these losses can represent a significant percentage of total compressed air consumption.
An ultrasonic leak audit helps:

  • Reduce energy consumption
  • Lower operating costs
  • Improve system reliability
  • Reduce compressor run time
  • Extend equipment life
  • Improve system pressure stability
  • Support sustainability initiatives

What Is Included in a Leak Audit?

Our compressed air leak audits typically include:

  • Facility walk-through
  • Ultrasonic leak detection survey
  • Leak tagging and identification
  • Estimated leak flow calculations
  • Annual energy cost estimates
  • Prioritized repair list
  • Summary report
  • Follow-up recommendations

How Ultrasonic Leak Detection Works

Compressed air leaks generate high-frequency sound waves that are typically inaudible to the human ear. COMAIRCO technicians use specialized ultrasonic leak detection equipment to locate leaks while your facility remains in operation.
Each leak is:

  • Identified
  • Tagged
  • Documented
  • Quantified
  • Prioritized for repair

The final report provides actionable recommendations that help maintenance teams focus on the costliest leaks first.

Compressed air leak audit report showing an identified air leak on industrial piping with estimated annual energy cost, tag number, location, and repair notes.Image courtesy of COMAIRCO.

How Much Can Compressed Air Leaks Cost?

In many Northeast manufacturing facilities, compressed air systems operate 24 hours per day. Even a small leak can waste thousands of dollars annually in electricity costs and increase compressor run time. Multiple undetected leaks can significantly impact plant energy consumption and production efficiency.

A structured leak management program can help facilities maintain leak losses below acceptable targets and continuously improve compressed air system efficiency.

A 1/4-inch compressed air leak can cost thousands of dollars annually in wasted electricity, depending on operating pressure, run time, and local utility rates. Identifying and repairing leaks is often one of the fastest-return energy efficiency projects available in an industrial facility.

Compressed air leak cost chart showing estimated annual energy costs for 1/16-inch, 1/8-inch, and 1/4-inch leaks at 100 psi, including flow rates in CFM and annual operating costs.Chart courtesy of COMAIRCO.

Compressed Air Leak Size Cost Examples

Common Sources of Compressed Air Leaks

Leaks are commonly found at:

  • Quick-connect fittings
  • Flexible hoses
  • Pipe joints
  • Valves
  • Regulators
  • Air dryers
  • Filters
  • Condensate drains
  • Pneumatic tools
  • Production equipment

Many facilities are surprised to learn that numerous small leaks can cost more than a single large leak.

Leak Audits and Compressed Air Audits

Compressed air leak audits are often performed alongside data-logged compressed air audits.
Combining both services allows facilities to:

  • Measure demand
  • Analyze system pressure
  • Evaluate compressor performance
  • Identify leak load
  • Improve energy efficiency
  • Plan future system upgrades

Find Hidden Compressed Air Leaks

Schedule a compressed air leak audit and ultrasonic leak detection survey with COMAIRCO. Our team helps Massachusetts manufacturers and industrial facilities reduce energy consumption, improve reliability, lower operating costs, and optimize compressed air system performance.

Request a Leak Audit

Industrial compressors

With more than 40 years of experience, Comairco is a true leader in North America.

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Used equipment

We have a wide range of air compressors, air dryers, tanks

and outdoor mobile stations designed for your air compressors,

as well as other used products in order

to help you out in emergency situations.

 

 

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Northeast Compressed Air Solutions

Compressed Air Services

Complete Compressed Air Services for Northeast Facilities

Whether you need emergency service, planned maintenance, system upgrades, temporary rental equipment, compressed air audits, or a fully managed AIRTILITY solution, COMAIRCO provides reliable support throughout the Northeast. Our solutions are designed to improve system efficiency, maximize uptime, and ensure dependable compressed air for mission-critical applications.

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