Pneumatics
Leakage Flow & Annual Cost
Calculate air loss and annual energy cost from a compressed air leak. Also calculates CO₂ equivalent and payback on repair.
Units:
A 1mm hole at 6 bar leaks ≈6–8 nl/min. At €0.02/m³ that is already €63/year for one tiny leak. A typical factory loses 20–30% of compressed air through leakage. Ultrasonic leak detection during production hours is the most effective survey method.
Annual cost [€] = Flow [m³/h] × operating hours/year × price [€/m³]
Input
Leak flow rate iTotal leak flow in nl/min. Measure using the compressor run-time method: pressurise system to max, switch off production, time how long before pressure drops by 1 bar, then calculate.
nl/min
Operating hours per year iTotal annual operating hours (when system is pressurised). 1 shift = ~2000h, 2 shifts = ~4000h, 3 shifts = ~6000h/year.
h/year
Compressed air price iCost to produce 1 m³ of compressed air. EU average including electricity, maintenance and depreciation: €0.015–0.025/m³. Ask your energy supplier for actual figure.
€/m³
Repair investment iEstimated one-time cost to locate and fix the leaks (labour + parts).
€
Result
Air wasted per year [m³]
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Annual energy cost [€]
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CO₂ equivalent [kg/year]
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Payback period [months]
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