Western Air Works uses ultrasonic leak detection to find exactly where your compressed air system is losing money — then fixes it. You get a written report with every leak quantified in dollars.
The average manufacturing facility loses 25–30% of its compressed air to leaks — air that was already pressurized, dried, filtered, and paid for. It exits through fittings, couplings, valves, and worn seals, completely silently at normal hearing frequencies.
Compressed air is the most expensive utility in most manufacturing operations — commonly cited at $0.25–$0.35 per 1,000 CFM in operating cost. Leaks don't just waste electricity. They force your compressor to run harder, shortening its service life and masking real system problems.
Most facilities run for years losing thousands of dollars annually to leaks that have never been located, because locating them requires equipment most maintenance teams don't have and a systematic survey approach that daily operations don't allow.
High-cycle pneumatic connections develop small gaps over time. A single 1/8" orifice at 100 PSI leaks approximately 25 CFM — enough to meaningfully load a mid-size compressor.
Pneumatic cylinders and solenoid valves develop internal bypassing as seals age. The leak is contained within the component — invisible and inaudible — but the compressor knows it's there.
Open-pipe blowoffs consume 3–5× more air than an engineered nozzle for the same application. They aren't leaks in the traditional sense — but they drain air system capacity just as effectively.
Long distribution runs accumulate small leaks at every connection point. Overhead locations are rarely included in routine maintenance walks. The losses compound silently across the full length of the system.
Failed pressure regulators cause facilities to run system pressure higher than needed to compensate — increasing leak rate across every point in the system and accelerating wear on downstream equipment.
Every engagement begins with a thorough survey. The findings determine what comes next — and every dollar spent on remediation is backed by documented savings data from the same visit.
A systematic ultrasonic survey of your entire compressed air distribution system — from the compressor room to every point of use. Every leak is logged by location, estimated CFM loss, and calculated annual energy cost at your facility's operating hours and utility rate.
Engineered EXAIR nozzles replace open-pipe blowoffs and worn point-of-use nozzles — reducing compressed air consumption 30–70% at each application point with no reduction in blowing or cooling performance. Retrofits are quoted at fixed price from survey findings.
Compressed air leaks return as equipment cycles, fittings loosen, and new pneumatic connections are added. An annual re-audit keeps your energy cost baseline locked in, ensures new leaks are found before they compound, and produces updated documentation for insurance and compliance purposes.
A straightforward four-step process. No disruption to your production schedule. No equipment you need to shut down. The survey runs while your system is operating under pressure — which is when leaks are actually present.
Brief call or walkthrough to understand your facility size, compressor count, operating hours, and current energy concerns. We determine the right survey scope and schedule access at a time that works with your production floor.
Systematic walk of your complete compressed air distribution system using the UE Systems Ultraprobe 100 — including overhead lines, confined connections, and all point-of-use equipment. Every leak is tagged, located, and logged in the field. Typical survey: 2–6 hours depending on facility size.
Within 48 hours, you receive a written report showing total annual leak cost in dollars, a prioritized repair list, nozzle retrofit opportunities with projected payback, and equipment condition observations. Formatted for management review, insurance submission, or compliance documentation.
A fixed-price retrofit quote for identified nozzle and blowoff opportunities is provided within 5 business days of the report. Leak repairs are completed on a scheduled return visit. Annual re-audit contract locks in your savings for future years.
The Air Efficiency Report is not a list of observations. It is a dollar-quantified business case — written so a plant manager, operations director, or CFO can immediately understand the financial impact and act on it.
Every report opens with the total annual energy cost of identified leaks — the single number that drives every conversation that follows.
Every leak is assigned an ID number, physical location, estimated CFM loss, annual dollar cost, and priority rating. The table is sortable by impact — so your maintenance team knows exactly where to start.
Retrofit recommendations include projected annual savings and payback period in months. Most nozzle retrofits pay back in under 12 months at current energy rates.
Reports are structured for use in energy management programs, utility rebate applications, FSMA 204 compressed air documentation, and commercial insurance submissions.
| ID | Location | CFM | $/Yr | Priority |
|---|---|---|---|---|
| L-01 | Press #3 pneumatic cylinder inlet | 8.5 | $1,020 | HIGH |
| L-02 | North header — coupling, zone 4 | 6.2 | $744 | HIGH |
| L-03 | Open-pipe blowoff, conveyor exit | 22.0 | $2,640 | HIGH |
| L-04 | Compressor room — filter drain valve | 4.1 | $492 | MED |
| L-05 | Spray station — worn nozzle tip | 11.0 | $1,320 | MED |
| + 6 additional leaks detailed on pages 3–5 | ||||
| Total — 11 leaks identified | $14,240 | |||
Any facility running a compressed air system at production pressure has leaks. These are the industries where compressed air consumption — and compressed air waste — runs highest.
CNC machining centers, laser cutters, press brakes, plasma cutting, pneumatic tooling, sandblasting, and parts washers run air-powered systems at high duty cycles. Every tool is a potential leak point. Leak probability is highest in this sector.
Bottling lines, pneumatic conveyors, packaging equipment, keg filling, and canning operations use compressed air throughout production. FSMA 204 compliance requirements make air system documentation a regulatory necessity, not an elective.
Pneumatic fastening systems, dust collection, finishing lines, kiln operations, and material handling equipment run continuous air demand. Long distribution runs in large production buildings accumulate leak losses at every joint.
Paint booths, spray guns, air tools, frame racks, and compressor banks run constant air demand across a multi-bay facility. Quick-disconnect couplings in heavy daily use are one of the highest-frequency leak sources in any shop.
Grain handling equipment, irrigation pump systems, cold storage facilities, and pneumatic conveying lines across Central and Eastern Oregon. Seasonal high-value operations with systems that run hard and are rarely audited.
Dental air compressors, medical gas distribution, and lab equipment run at higher pressures with tighter cleanliness requirements. Small leaks at elevated pressure carry disproportionate annual cost relative to facility size.
There is no other dedicated compressed air audit and remediation service in Central Oregon. Here's why that matters to your operation.
Compressor dealers who offer "free surveys" are selling you a new compressor. Western Air Works sells no compressors, no air systems, and no equipment. Our only product is an accurate assessment of what your current system is costing you.
Portland-area energy consultants charge travel time and mileage on top of their survey fees to service Central Oregon. Western Air Works is based in Bend — your survey cost goes to the survey, not to I-97.
Your maintenance team fixes leaks they notice. We survey every line, every fitting, every overhead run, and every point of use — systematically, with calibrated ultrasonic equipment that detects what the human ear cannot.
The Air Efficiency Report documents exactly how much your leaks are costing you annually. That number — not our quote — is what makes the decision to proceed with retrofit obvious. The survey pays for itself the day you act on it.
A mid-size facility survey that identifies $12,000/year in leak losses returns its cost many times over in Year 1 alone — before a single repair is made.
Food Safety Modernization Act Section 204 compliance requirements include documentation of compressed air systems used in direct food contact, packaging, and production environments. The compliance deadline is July 2028 — and documented air quality and efficiency audits are a required component, not an optional best practice.
For breweries, beverage producers, food packagers, and any facility where compressed air touches the product or packaging line, a Western Air Works Air Efficiency Report provides ready documentation for FDA compliance submissions and third-party audits.
Facilities using compressed air in direct or indirect food contact applications face documentation requirements for air quality, system condition, and maintenance records. A written Air Efficiency Report fulfills this requirement.
Pneumatic conveyors, bottling lines, and packaging equipment using compressed air in proximity to open product require documented air system audits as part of FSMA 204 traceability recordkeeping.
Western Air Works reports are structured to satisfy third-party food safety auditors. Facility, system, methodology, findings, and technician credentials are all documented in a format auditors recognize.
Pacific Power and Oregon utility rebate programs require documented compressed air improvements for rebate claims. Our report provides the baseline measurement and post-retrofit documentation the utility requires.
Every survey quote is presented alongside the typical annual energy savings we find in facilities of similar size and type. The survey investment is measured against leak losses — not against competitors.
We never lead with our fee. We lead with the dollar value of what we typically find in a facility your size — and let you decide whether the survey makes sense. In most cases, the first year's energy savings from acting on our findings covers the survey cost many times over. Request a quote and we'll give you a same-day estimate based on your facility's square footage, compressor count, and operating hours.
Quoted by scope after survey findings. EXAIR nozzle parts sourced before the retrofit visit. No hourly billing — no scope surprises.
Annual re-audit contracts lock in a flat annual rate per facility. Protects your energy cost baseline year over year. No price creep.
We're offering complimentary baseline surveys to qualifying Central Oregon facilities. Find out what your leaks are costing you — at no charge. Limited availability.
Tell us about your facility and we'll respond within one business day with a survey scope and quote. No commitment required. Complimentary baseline surveys available for qualifying Central Oregon facilities.
No commitment required. Complimentary baseline surveys available for qualifying facilities. We respond within one business day.