Find Every Leak. Know Exactly What Each One Costs You
Ultrasonic leak detection across your entire compressed air system. Every leak tagged, photographed, quantified in litres per second, and costed in pounds per year. You get a prioritised repair list and a clear payback figure.
You Are Paying for Air That Never Reaches a Tool
Most compressed air systems lose between 20 and 40% of their output through leaks. Not catastrophic blowouts you can hear, but hundreds of small leaks across pipework, joints, fittings, hoses, and equipment connections. Each one costs money every hour the compressor runs.
You cannot fix what you cannot find. And you cannot justify the repair cost without knowing what each leak is actually costing you. That is why most leak programmes stall. The maintenance team knows there are leaks but cannot quantify the waste, so the budget never gets approved.
LeakSafe gives you the numbers. Every leak tagged, quantified, and costed so you can prioritise repairs by payback and prove the savings to your finance team.
How LeakSafe Works
Our engineers use industrial ultrasonic detection equipment to survey your entire compressed air distribution system. Every leak is tagged with a unique reference, photographed, and measured in litres per second. We then calculate the annual energy cost of each leak based on your actual electricity rate and compressor efficiency. To put the numbers in context: a single 1mm diameter leak at 7 bar operating pressure wastes approximately 0.2 litres per second and costs around £400 per year in electricity. A 3mm leak wastes approximately 1.6 litres per second and costs over £2,000 per year. A 6mm leak costs upwards of £8,000 per year. Most sites have dozens or hundreds of small leaks that individually seem insignificant but collectively waste 20 to 40% of total compressor output.
Our engineers use SDT and Leakshooter ultrasonic detectors capable of identifying leaks in noisy factory environments up to 95 dB. Each leak is marked with a numbered aluminium tag that stays in place until repair, so your maintenance team can locate every leak from the report map.
You receive a prioritised repair list ranked by cost impact, a site leak map showing every tagged location, and a summary showing total system leakage as a percentage of output. Repairs can be quoted separately or included in your Uptime Protection plan. The survey fee is credited against any repair work completed within 60 days.
Pre-Survey Scope
We confirm the extent of your compressed air distribution, note any restricted access areas, and agree the survey schedule around your production hours. No disruption to your air supply.
Ultrasonic Survey
Engineers systematically scan every joint, fitting, connection, valve, and hose across your pipework network. Each leak is tagged with a numbered marker, photographed, and measured.
Quantification and Costing
Every leak is converted from litres per second into kilowatt hours and pounds per year using your actual electricity rate. Total system leakage is expressed as a percentage of compressor output.
Report and Repair List
Written report with a site leak map, individual leak cards, total annual cost, and a prioritised repair list ranked by payback. Delivered within 10 working days, guaranteed.
Repair and Verify
We quote repairs separately or include them in your service plan. After repairs, a verification survey confirms the leaks are sealed and quantifies the actual energy recovered.
Proof, Not Promises
Real results from real contracts. Numbers our clients can verify.
Annual leak detection surveys across all 30 Costco warehouses as part of the national PPM contract. Leak data feeds directly into the quarterly reporting cycle, with repairs prioritised by cost impact across the estate.
Read the full case studyFrequently Asked Questions
How much could we save by fixing compressed air leaks?
Most sites recover between 20 and 30% of wasted compressed air energy after a leak survey and repair programme. As a benchmark, a factory running a 75 kW compressor at 7 bar with 30% leakage is wasting approximately 22 kW of electrical input continuously. At 12p per kWh over 6,000 running hours per year, that is roughly £16,000 per year in wasted electricity. Even a partial repair programme targeting the top 10 leaks by size can recover 50 to 70% of that waste within the first month. We have never surveyed a site and found nothing worth fixing. The report quantifies the savings in pounds so you can see the payback before committing to repairs.
Will the survey disrupt production?
No. Ultrasonic detection works while the system is running under normal operating pressure. In fact, the system needs to be pressurised for accurate results. Our engineers work around your production schedule with no downtime required.
How often should we do a leak survey?
We recommend annually for most sites. Compressed air systems develop new leaks at a rate of roughly 3 to 5% of total system leakage per year in a typical industrial environment. Vibration, thermal cycling, connection wear, and hose degradation all contribute. An annual survey catches new leaks before they accumulate to the point where your compressors are working significantly harder than they need to. Without regular surveys, a system repaired to near zero leakage can return to 15 to 20% leakage within three to four years.
Can you fix the leaks as well as find them?
Yes. We can quote repairs separately after the survey, or include leak repair as part of your Uptime Protection service plan. The survey fee is credited against any repair work completed within 60 days, so the survey effectively pays for itself if you act on the findings.
What equipment do you use?
We use industrial grade ultrasonic leak detectors that identify leaks by the 40 kHz ultrasonic frequency generated when compressed air escapes through an orifice. This frequency is above ambient factory noise, allowing detection in environments where you cannot hear the leak with the human ear. Each detected leak is measured using flow rate calculations based on orifice size estimation and system pressure, then converted to kWh and pounds per year using your actual electricity rate. The equipment can detect leaks as small as 0.1 litres per second. This gives you accurate cost data rather than a vague list of locations.
Find Out What Your Leaks Are Really Costing You
One call. We will discuss your site, agree the survey scope, and give you a fixed price. No obligation, and the survey fee is credited against repairs.