How do you calculate the cost of a compressed air leak?

Multiply the leaked volume by the cost per unit, scale by the fraction of time the leak runs, then add fixed repair cost. With 100 units at $45, an 80% duty factor and $250 fixed, the total is $3,850.

What is a good leak cost target?

There is no good leak — the goal is zero. Most plants aim to keep total air-leak losses under 10% of compressor energy; any leak with a high per-unit cost like the $38.50/piece here should be repaired in the next maintenance window.

Why include a duty factor?

Leaks only cost money when the system is pressurized. The duty factor — 80% in the example — scales the loss to the share of time the line is actually live, so a leak on an intermittently used circuit is not overstated.

What is the per-unit leak cost telling me?

It is total cost divided by leaked volume, here $38.50 per unit. It lets you compare leaks of different sizes on a like-for-like basis and rank repairs by cost-effectiveness.

Hydraulic leak vs air leak cost?

Both use the same math, but hydraulic leaks add disposal, contamination, and housekeeping costs into the unit cost, while air leaks are almost entirely compressor energy. Set the unit cost accordingly.

Should the fixed cost include labor?

Yes — fold technician time, replacement fittings, and any production interruption into the $250 fixed cost so the total reflects the true repair burden, not just the lost media.

Hydraulic, Pneumatic & Fluid Power Systems calculator

Leak Cost Calculator

Leak Cost converts a compressed-air or hydraulic-fluid leak into an annual or per-period dollar figure by combining leaked volume, the cost of that media, the fraction of time the leak is actually live, and the fixed cost to fix it. Plant engineers and energy managers use it to justify a leak-survey program, because compressed air is one of the most expensive utilities on the floor and 20-30% of generated air is commonly lost to leaks. The metric matters because a single 1/8-inch orifice can quietly cost thousands a year in compressor energy. It puts a number on something maintenance can otherwise ignore until the bill arrives.

What this calculator does

Calculate leak cost for hydraulic, pneumatic & fluid power systems planning, quoting, troubleshooting, capacity review, or process improvement.
Use it when leak cost in hydraulic, pneumatic and fluid power systems is being put through a hydraulic, pneumatic and fluid power systems weighted-cost review.
It computes the total cost of a leak — leaked volume times unit cost times duty factor plus fixed repair cost — and the per-unit cost of that leaked media.

Formula used

Leak Cost cost = quantity × rate × capture factor + fixed cost
Per-unit leak cost = total cost ÷ quantity

Inputs explained

Leaked air or fluid volume:
Cost per unit of leaked media:
Continuous-leak duty factor:
Fixed repair and labor cost:

How to use the result

Use it after an ultrasonic or flow survey gives you a leak rate, to prioritize which leaks to tag and repair first.
It assumes a steady leak rate and a single unit cost; real compressed-air costs vary with compressor loading, ambient conditions, and tariff time-of-use rates.

Current U.S. benchmarks

The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate the cost of a compressed air leak? Multiply the leaked volume by the cost per unit, scale by the fraction of time the leak runs, then add fixed repair cost. With 100 units at $45, an 80% duty factor and $250 fixed, the total is $3,850.
What is a good leak cost target? There is no good leak — the goal is zero. Most plants aim to keep total air-leak losses under 10% of compressor energy; any leak with a high per-unit cost like the $38.50/piece here should be repaired in the next maintenance window.
Why include a duty factor? Leaks only cost money when the system is pressurized. The duty factor — 80% in the example — scales the loss to the share of time the line is actually live, so a leak on an intermittently used circuit is not overstated.
What is the per-unit leak cost telling me? It is total cost divided by leaked volume, here $38.50 per unit. It lets you compare leaks of different sizes on a like-for-like basis and rank repairs by cost-effectiveness.
Hydraulic leak vs air leak cost? Both use the same math, but hydraulic leaks add disposal, contamination, and housekeeping costs into the unit cost, while air leaks are almost entirely compressor energy. Set the unit cost accordingly.

Last reviewed 2026-05-12.