Home / Our Services / Flow Monitoring for Air Compressors

Flow Monitoring for Air Compressors

Save Energy, Reduce Costs, and Prevent Breakdowns

Did you know that compressed air systems can waste up to 30% of energy through undetected leaks?

Why Monitor Air Compressor Flow?

Flow monitoring for air compressors gives you real-time insights into your system. Often called the ‘fourth utility’ alongside electricity, water, and gas, compressed air is one of the most expensive resources an industrial facility generates, and it often goes unmonitored. This allows you to spot inefficiencies, quantify your leakage rate, prevent costly breakdowns, and reduce your bills.

Compressed air accounts for around 10% of industrial electricity consumption, costing around £0.02 per cubic metre of air generated. Without monitoring, you could be wasting thousands of pounds a year. Across UK industry, this waste translates to a financial loss of over £2.6 million every single day.

Benefits of Air Compressor Monitoring Systems

Energy Savings

Identify and eliminate waste. Most systems have the potential to save up to 30% on electricity

Leak Detection

Use real-time data to find and fix costly leaks fast. A single 1.5 mm leak can cost over £2,000 per year.

System Optimisation

Use data on your air demand profile to get your compressors running at their best and avoid inefficient ‘unloaded’ running.

Predictive Maintenance

Monitor the status of your compressed air equipment to spot anomalies before they cause a shutdown, extending the life of your compressor.

Guarantee Air Quality

Ensure the quality of air by monitoring key parameters like dew point, crucial for food, pharma, and electronics manufacturing.

Complete Monitoring and Control of your Compressed Air Monitoring Systems

Even small leaks can cost your business thousands of pounds a year. A 1/4 inch leak at 100 pounds per square inch (psi) can cost over £6,000 annually. A flow monitoring system pays for itself in 6–12 months through energy savings alone. Below are some common air compressor problems you can avoid when you have complete control via a flow monitoring system.

Low CFM (cubic feet per minute) Output

Cause

Clogged intake air filter, leaks, worn compressor

Risk

Machines do not work properly, production slows down

Solution

Regular filter cleaning and flow measurement to check air delivery and volumetric flow

High Energy Bills

Cause

Poor compressor efficiency, air leaks, wrong-sized system

Risk

Wasting money every month. This is often caused by ‘artificial demand’ – the volume of air wasted by leaks, which forces compressors to run longer and at a higher pressure just to compensate.

Solution

Flow monitoring to track the consumption of compressed air, fix leaks, and correctly size your system.

Water in Air Lines

Cause

No dry air dryer, bad dew point

Risk

Rusty tools, damaged products, shorter equipment life

Solution

Install proper dryer, add dew point sensor monitoring

Inconsistent Pressure

Cause

Leaks, improper sizing, high air consumption

Risk

Product quality issues, machine damage

Solution

Monitor compressed air flow rateand pressure loss across the system, right size your system. This prevents operators from incorrectly increasing the compressor discharge pressure above the required operating pressure, which only wastes more energy.

Our Flow Monitoring Solutions

Thermal Mass Flow Meters

Advanced Flow Meter Technology

We supply and install industry-leading monitoring equipment:

The standard for energy management. These meters measure mass flow directly (e.g., in SCFM or Sm³/h) without needing pressure compensation. Their high accuracy and excellent sensitivity at low flow rates make them ideal for measuring leak loads.

Ultrasonic Air Flow Meters

Available as non-invasive ‘clamp-on’ models. These can be installed on the outside of a pipe with no downtime, making them a perfect solution for surveys, diagnostics, or critical systems that cannot be shut down.

Differential Pressure Meters

A traditional technology (like an orifice plate) used for basic monitoring. While inexpensive, they can create a permanent pressure loss (wasting energy) and have poor accuracy at low flow rates.

Dew Point Sensors

detect when air is about to form water droplets, helping prevent equipment damage and extend machine life. This is critical for quality control, ensuring your air treatment (dryers, filters) is working effectively to protect your final product.

SMARTLINK is like having a 24/7 expert watching your air compressor system

This remote monitoring service connects to your compressed air equipment (like a rotary screw GA VSD+ or ZT series oil-free compressor) and sends real-time data to you and our service team.

SMARTLINK is available in different levels to suit your needs:

SMARTLINK Service: Provides a service timeline and digital logbook.
SMARTLINK Uptime: Delivers real-time alerts to prevent downtime.
SMARTLINK Energy: Offers detailed reports to track energy efficiency.

For a complete picture, this can be combined with SMART AIRnet sensors, which extend monitoring into your pipework to measure flow and pressure at the point of use.

Stop problems before they cause downtime

Real-Time Alerts – instantly notify you about air leaks or pressure drops.

Ensure you get the air flow you need

Performance Tracking – measures CFM output and air delivery constantly.

Avoid unexpected repairs and production shutdown

Predictive Maintenance – identifies potential issues before they cause breakdowns.

Detect efficiency issues that waste money

Energy Monitoring – tracks exactly how much power your compressor uses.

50 Years Experience

Why Work With Us?

One of the largest independent Fluid Power companies operating in the United Kingdom
Atlas Copco Premier Distributors
Diverse Market Coverage including 9 key specialisms

Frequently Asked Questions

How do I know if my compressed air system needs flow monitoring?

If you are experiencing pressure fluctuations, high energy bills, or frequent breakdowns, flow monitoring will identify the root cause. Most customers achieve 15–30% energy savings.

Will installing flow meters disrupt our operations?

Most modern flow meters can be installed with minimal disruption. Our ultrasonic and clamp-on options require no system modifications and can be fitted during normal operation or scheduled maintenance breaks. Even inline meters like thermal mass can be installed via a ‘hot-tap’ method, which also prevents a shutdown.

Can flow monitoring integrate with our existing building management system?

Yes. Our solutions are compatible with all major BMS, SCADA and PLC systems. We can output data via Modbus, 4-20mA, or other protocols to ensure seamless operation and data sharing.

How quickly will I see a return on investment?

Through energy savings, most customers see a full return within 6–12 months. Systems with significant undetected leaks often see payback in as little as 3 months.

Get In Touch

What Sets Control Gear Apart: Expert Service

1. System Audit

Our engineers will conduct a full assessment of your existing compressed air system, often following the framework of an ISO 11011 energy audit:

Full system pressure testing
Current energy consumption analysis using non-invasive data loggers to capture a true load profile
Air quality assessment
Comprehensive leak detection survey

2. Customised Monitoring Solution

Based on your specific requirements and audit findings, we will design a monitoring package that:

Transforms raw compressor data into actionable intelligence
Integrates with your existing equipment
Scales with your usage
Provides the data you need to achieve your business goals
Fits your budget

3. Installation and Training

Our certified technicians will:

Install all monitoring equipment with minimal downtime
Calibrate systems for accurate readings
If required, integrate data with your existing SCADA or BMS platforms
Train your staff on dashboard usage and data interpretation
Provide full documentation and support materials

4. Ongoing Support and Maintenance

We do not just install and leave:

Regular system check-ups and recalibration
Software updates and technical support
Quarterly efficiency reports with actionable insights to ensure savings are sustained and new opportunities are identified
Proactive maintenance recommendations

Get in touch

Contact Us

We offer Guardian Service, our industry-leading service plan that provides fixed annual service and warranty coverage for up to 9 years with no hidden costs.

Visit us Heol Groeswen, Treforest Industrial Estate, Pontypridd, Rhondda Cynon Taff, CF37 5YF
Call us 01443 843126
Email us enquiries@control-gear.com

Mon–Fri · 09:00–17:00
24/7 emergency call-out available

What does a monitoring system include?

Instant alerts for pressure drops, leaks and unusual usage patterns
Historical trend analysis to optimise compressor scheduling and improve the performance of your system
Energy efficiency tracking with detailed savings reports to verify your ROI

Control Gear delivers flow monitoring solutions and complete air compressor flow management systems

across South Wales and the West, including Cardiff, Newport, Swansea, Bristol, Stroud and Swindon.

Control Gear Quality Guarantee

Industry-leading certifications back our commitment to excellence:

Environmental Management – ISO 14001
Quality Management – ISO 9001
Occupational Health and Safety – ISO 45001
All engineers are F-Gas certified