Identifying Critical Compressed Air Leaks to Reduce Energy Losses
In Battery Manufacturing Industry
Application
Compressed air system leak detection and management solution.
Goal
Enable leak visibility, reduce waste, and improve efficiency.
Customer
A battery power manufacturer.
Sector
Battery manufacturing.
Overview and Challenges
1. Overview
The manufacturing park operates multiple compressed air systems with a total capacity of nearly 400 m³/min, running continuously at full load. Air leaks are common, particularly at end-use points such as fittings and tools, leading to significant cumulative energy losses.
2. Challenge of the Customer
Leak detection relies on manual inspection, which is inefficient and easily affected by noisy environments, resulting in missed leak points. At the same time, new leaks continue to occur due to system aging and lack of continuous monitoring, making long-term management difficult.
In addition, the absence of clear quantification of energy losses limits decision-making and makes it challenging to prioritize corrective actions.
3. Solution and Implementation
To address low inspection efficiency, difficulty in locating leaks, and challenges in quantifying losses, the S532 acoustic imaging leak detector is introduced to build an efficient and intuitive leak detection and management system.
The S532 acoustic imaging leak detector is used for regular full-coverage inspections of the compressed air system, quickly identifying high-risk leak points such as fittings, valves, and pneumatic tools. Leak points are recorded and tracked in a closed-loop process, while reports and data analysis support continuous optimization.
- Acoustic imaging visualization: Converts compressed air leaks into visual images for fast remote scanning and precise localization, greatly improving detection efficiency.
- Multi-mode detection: Supports both compressed air/gas leak detection and electrical partial discharge detection, allowing one device to handle multiple inspection tasks in complex industrial environments.
- Laser-assisted targeting: Equipped with an integrated laser pointer to help operators quickly identify and accurately pinpoint leak locations during on-site inspections.
- Data recording and image capture: Records photos and screenshots for complete documentation, analysis, and traceability.
Powerful Reporting and Documentation
The S532 acoustic imaging leak detector supports intelligent report generation. Inspection data can be automatically converted into standardized PDF reports, providing clear visualization of leak locations, severity, and improvement results, and enabling effective management decision-making and reporting.
4. Results
By introducing acoustic imaging leak detection technology and systematic management methods, the factory has achieved remarkable results in the control of compressed air leaks
Critical Leaks Detected
Four leaks with a combined leakage rate of 104.73 l/min were identified. Three critical leaks accounted for 102.65 l/min, enabling maintenance teams to focus on the largest sources of compressed air loss.
Fix Priority
Quantified leakage rates and severity classifications provided a clear basis for prioritizing repairs and focusing resources where they matter most.
Fast Leak Detection
Acoustic imaging enabled operators to quickly scan installations and visually locate leaks, even in noisy production environments.
Data Driven
Images, measurement data, and standardized reports created traceable inspection records and supported systematic, long term leak management.
5. Conclusion
“By introducing detection tools capable of quantifying leak volume and associated costs, we have not only improved leak detection efficiency, but also achieved a transition from experience-based management to data-driven operations—providing a practical and effective pathway toward a ‘Zero-Leak Factory.’”
— Facility Management Lead
6. Products in Use
The following SUTO iTEC solution was used to detect, quantify, and manage compressed air leaks throughout the manufacturing facility.
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Reduce Energy Losses with Acoustic Imaging Leak Detection
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