How much air does a 1/8 inch leak waste?

At 100 psig a 1/8 in orifice passes roughly 25 CFM, which is around 6–7 compressor horsepower running continuously.

What percentage of compressed air is typically lost to leaks?

Poorly maintained plants commonly lose 20–30% of output to leaks; a well-managed system holds it under 10%.

How do I find leaks without a detector?

Run a leak-down test with all tools off, time how long the system stays loaded, and use soapy water on fittings, quick-connects, hose ends and drain valves.

Air Compressor Leak Cost Calculator — $ per Year

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Formula

CFM ≈ 28 × d² × P_abs × 0.52 (sharp-edged orifice, choked flow @ 100 psig)

Unit system

Hole diameter

kW per CFM

kW/cfm

$ / kWh

$/kWh

Hours / year

Leak rate

6.52CFM

Annual cost

$1509

At 100 psig continuous.

How to use this calculator

Convert leak size and count into wasted CFM, kWh and annual dollars.

Enter the estimated orifice size for each leak or the load/unload duty cycle from a leak-down test.
Enter the system pressure and the number of leaks of that size.
Enter electricity cost and annual run hours.
Read wasted CFM and the annual cost of the leak load.

Frequently asked questions

How much air does a 1/8 inch leak waste?: At 100 psig a 1/8 in orifice passes roughly 25 CFM, which is around 6–7 compressor horsepower running continuously.
What percentage of compressed air is typically lost to leaks?: Poorly maintained plants commonly lose 20–30% of output to leaks; a well-managed system holds it under 10%.
How do I find leaks without a detector?: Run a leak-down test with all tools off, time how long the system stays loaded, and use soapy water on fittings, quick-connects, hose ends and drain valves.