Accident Repair Centre Saves £7,173 Annually Through Air Leak Survey
How We Helped a Local Body Shop Cut Compressed Air Costs by 76%
When an accident repair centre in our service area contacted us about rising energy costs, we knew exactly where to look. Compressed air systems are the lifeblood of body shops, powering everything from spray guns to pneumatic tools. But they’re also notorious for wasting energy through air leaks.
The Challenge
The facility was operating a 7 Bar compressed air system around the clock to keep up with their repair schedule. Like many busy workshops, they suspected they had leaks but didn’t know the extent of the problem or where to start fixing them.
Our Approach
Our team carried out a comprehensive ultrasound air leak survey of the entire compressed air system. Using specialist ultrasonic detection equipment, we identified 29 individual air leaks across the facility, each one quietly draining money and energy.
The Results
The survey revealed significant opportunities for savings:
29 air leaks identified across the compressed air system
19 leaks repaired during our initial visit (66% completion rate)
£7,173 in annual cost savings from the repaired leaks alone
£9,423 total potential savings if all leaks are addressed
Breakdown by Severity
23 minor leaks
5 moderate leaks
1 major leak
Accident Repair Centre Saves £7,173 Annually Through Air Leak Survey
The Solution: Prevost ESI 07 Safety Couplings
The majority of leaks we discovered were traced back to worn and failing couplings, a common problem in busy workshops where tools are constantly connected and disconnected throughout the day.
Rather than simply patching up the old couplings, we upgraded the facility to Prevost ESI 07 safety quick-release couplings. These aren’t your standard pneumatic fittings. They’re specifically designed to eliminate the coupling failures that cause air leaks.
Key Benefits of the Prevost ESI 07 System:
3-year leak-free warranty: Guaranteed performance.
Automatic connection: Effortless coupling that resists vibration and corrosion.
Innovative sealing: A mechanism with Prevost plugs that eliminates leak risk.
No pressure loss: Efficient air pass-through.
Anti-hose whip technology: Enhanced workplace safety.
Colour-coded buttons: Prevents connection errors and reduces accidents.
The upgrade means this accident repair centre now has a compressed air system that won’t just save them money today, but will continue delivering leak-free performance for years to come.
What This Means for the Business
By repairing just two-thirds of the identified leaks and upgrading to Prevost ESI 07 safety couplings, the accident repair centre is now saving over £7,000 every year. That’s money that was literally disappearing into thin air before our survey.
The remaining 10 unrepaired leaks represent another £2,250 in annual savings waiting to be captured. With the new coupling system in place, these final repairs will deliver long-term, guaranteed leak-free performance.
The best part? The 3-year leak-free warranty on the Prevost couplings means the facility won’t be fighting the same battles with failing couplings year after year. It’s a one-time fix that keeps on saving.
The Environmental Impact
Beyond the financial savings, fixing these air leaks delivers real environmental benefits. Compressed air is one of the most energy-intensive utilities in manufacturing and automotive repair. Every leak we eliminate means less electricity consumption and a smaller carbon footprint.
Why Air Leak Surveys Matter
This case study demonstrates why compressed air systems should never be ignored. Even well-maintained facilities can develop dozens of leaks over time as hoses age, fittings loosen, and connections wear out. You can’t fix what you can’t find, and most air leaks are completely silent to the human ear.
For businesses looking to stay ahead of these issues, air leak surveys can be included as part of our comprehensive service agreements, providing scheduled detection and preventive maintenance before leaks impact your bottom line.
The Coupling Problem
In our experience, faulty couplings are one of the most common sources of compressed air leaks. Every time a tool is connected and disconnected, the coupling wears a little more. O-rings degrade, seals fail, and before long you’ve got dozens of connection points quietly bleeding air 24/7. Standard couplings simply aren’t designed for the punishment they receive in busy workshops.
Our ultrasound detection equipment picks up the high-frequency sound of escaping compressed air, allowing us to pinpoint leaks with precision and quantify exactly how much each one is costing you. Once we know where the problems are, we can recommend the right solution, whether that’s repairs, replacements, or upgrading to professional-grade components like Prevost safety couplings.
Infrared image identifying an active compressed-air leak detected during our site survey
Is Your Compressed Air System Leaking Money?
If you operate a compressed air system in Yorkshire, the East Midlands, or the Northwest, we can help you identify where you’re losing money. Our air leak surveys provide a complete picture of your system’s efficiency, with detailed reports showing the location, severity, and annual cost of every leak.
Get in touch with Search Air today to arrange your air leak survey and start saving money.
About Search Air
Search Air has been serving the compressed air industry for 78 years. As an Atlas Copco Premier Distributor and employee-owned company, we combine technical expertise with a genuine commitment to helping businesses reduce their energy costs and environmental impact.
Based in Leeds with depots across Yorkshire, Nottinghamshire, Lancashire, and Greater Manchester, we provide compressed air equipment, service, and energy-saving solutions throughout Northern England.