Consider this: The amount of electrical energy required to create compressed air to run an air drill is approximately 7 times more than if an electric drill was used. Sometimes, for safety or other reasons, a compressed air drill is needed, but it is important to control leaks, and optimize the system, by selecting the correct operating pressures, filter regulators, pipe diameters, etc. — and by establishing a strong Leak Prevention Program. (Most industrial applications without a Leak Prevention Program lose 20% to 30% of their air in leaks.) For a customer paying $0.158 per kWh, leaks can be a significant cost. For instance, for a single hole, the annual costs are as follows:
| Hole Diameter | Annual Cost |
|---|---|
| 1/16 inch (1.5 mm) | $1,652 |
| 1/8 inch (3 mm) | $6,620 |
| 1/4 inch (6 mm) | $26,488 |
(Ref: Best Practises for Compressed Air Systems, 2nd Edition, Page 75)