Illustrative scenario
Compressed air leaks in a stamping operation
Illustrative scenario — representative of common industrial IoT applications
Compressed airManufacturing — automotive, plastics & rubberMetal Fabrication & Finishing
The most expensive utility per unit of work, leaking into an empty building overnight.
A Tier 2 automotive stamping plant
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
Compressed air has no meter on most plant floors and no smell when it escapes. The compressor simply runs longer.
02
Cost
20–30% of compressor output — The commonly cited leakage share in industrial compressed-air systems.
03
Fix
Header pressure transducer · Compressor current monitoring for runtime and load · Off-shift flow trending
04
Restored
A leak-repair list ranked by measured loss
In full.
Illustrative scenario — representative of common industrial IoT applications.
The problem
Compressed air has no meter on most plant floors and no smell when it escapes. The compressor simply runs longer.
What would be installed
- Header pressure transducer
- Compressor current monitoring for runtime and load
- Off-shift flow trending
What changes
Before — A compressor that cycles all night for no production After — A leak-repair list ranked by measured loss
The number
20–30% of compressor output — The commonly cited leakage share in industrial compressed-air systems. Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
In one line
Nobody hears a leak over a stamping press. Everybody sees it on an off-shift trace.
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
| Interval | Compressor 1 (kW) | Compressor 2 (kW) |
|---|---|---|
| 00:00 | 74 | 43 |
| 00:30 | 68 | 45 |
| 01:00 | 72 | 43 |
| 01:30 | 69 | 44 |
| 02:00 | 69 | 47 |
| 02:30 | 68 | 42 |
| 03:00 | 70 | 42 |
| 03:30 | 74 | 45 |
| 04:00 | 74 | 46 |
| 04:30 | 73 | 45 |
| 05:00 | 73 | 45 |
| 05:30 | 71 | 46 |
| 06:00 | 85 | 58 |
| 06:30 | 90 | 59 |
| 07:00 | 89 | 63 |
| 07:30 | 85 | 61 |
| 08:00 | 86 | 62 |
| 08:30 | 90 | 58 |
| 09:00 | 88 | 58 |
| 09:30 | 88 | 59 |
| 10:00 | 88 | 62 |
| 10:30 | 90 | 61 |
| 11:00 | 86 | 58 |
| 11:30 | 90 | 60 |
| 12:00 | 89 | 61 |
| 12:30 | 88 | 62 |
| 13:00 | 90 | 60 |
| 13:30 | 88 | 61 |
| 14:00 | 85 | 61 |
| 14:30 | 90 | 64 |
| 15:00 | 87 | 62 |
| 15:30 | 91 | 62 |
| 16:00 | 89 | 60 |
| 16:30 | 86 | 63 |
| 17:00 | 90 | 59 |
| 17:30 | 87 | 62 |
| 18:00 | 89 | 64 |
| 18:30 | 85 | 63 |
| 19:00 | 88 | 61 |
| 19:30 | 88 | 60 |
| 20:00 | 86 | 60 |
| 20:30 | 88 | 58 |
| 21:00 | 90 | 64 |
| 21:30 | 86 | 60 |
| 22:00 | 69 | 42 |
| 22:30 | 71 | 47 |
| 23:00 | 73 | 45 |
| 23:30 | 72 | 42 |
| Before | A compressor that cycles all night for no production |
|---|---|
| After | A leak-repair list ranked by measured loss |
Illustrative dataset — a representative operational profile, seeded and deterministic, not measured at any site.
What changed.
Before
A compressor that cycles all night for no production
After
A leak-repair list ranked by measured loss
20–30%
of compressor output
The commonly cited leakage share in industrial compressed-air systems.
Source: Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
Compressed airNatural gasMetal Fabrication & FinishingBuilding Materials & Heavy Industry
A furnace over-cycling, seen on the air and gas traces together
A heat-treating operation
Short-cycling that neither the gas bill nor the air system showed alone.
2 utilitieson one chart
Illustrative scenario
Compressed airWaterFood & Beverage ProcessingBulk Handling & Rail Logistics
Over 450,000 litres saved in four months — and the clearest compressor graph we've produced
PDI Bulk
>450,000 litres of water saved in four months, and the clearest before/after compressor graph we've ever produced.
>450,000 Lin 4 months
Find out what’s hiding in your plant.
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