Episode 37: Five Costly Mistakes in Compressed Air Savings

Jason Reed

Welcome back to The Big Dog Podcast, everyone! I’m Jason Reed, here with Lisa Saunders, and today we’re talking about something that, honestly, we see way too often—people trying to save money on compressed air systems in all the wrong ways. Lisa, you wanna kick us off?

Lisa Saunders

Yeah, let’s get right into it. I mean, the first thing that always comes up is downsizing maintenance staff. It sounds like an easy budget win, right? But, in reality, you’re just losing expertise that you can’t get back. I visited a plant not too long ago—great team, but they’d let a couple of their senior techs go to cut costs. Within six months, they had a breakdown that nobody on the new crew could diagnose. The downtime alone cost them way more than those salaries ever would’ve.

Jason Reed

Yeah, and it’s not just about the headcount. It’s the knowledge that walks out the door. You can automate some stuff, sure, or bring in a consultant for the big jobs, but if you don’t have people who know your system inside and out, you’re just asking for trouble. And, honestly, you can’t outsource everything. There’s always that one weird noise or pressure drop that only your in-house guy knows how to handle.

Lisa Saunders

Exactly. And then there’s the temptation to use off-brand or pirated parts. I get it—OEM parts can seem pricey. But, especially in sensitive applications like electronics or food processing, you’re risking way more than you’re saving. I saw a plant where they swapped in a pirated valve—just one part—and it led to a shutdown. Not only did they void their warranty, but the production and maintenance budgets took a hit. It’s like, the money you “save” on that part is the most expensive money you’ll ever spend.

Jason Reed

Yeah, and that’s not just a scare tactic. Most manufacturers, Kaishan included, require OEM parts to keep your warranty valid. You start cutting corners there, and you’re on your own when something goes sideways. Plus, those parts are engineered for a reason—they’re not just random pieces of metal. You compromise the design, you compromise the whole system.

Lisa Saunders

And it’s not just about the compressor, either. It’s the downstream tools, the quality of your air, the safety of your people. So, yeah, cutting corners might look good on a spreadsheet, but it’s a false economy. You end up paying for it one way or another.

Jason Reed

Let’s talk about another classic mistake—oversizing equipment. I mean, we’ve seen this a lot, right? Folks buy a bigger compressor than they need because they’re planning for “future growth.” But what actually happens is you get short cycling, wasted energy, and a whole lot of money tied up in equipment that’s not doing you any favors.

Lisa Saunders

Yeah, and it’s so common. People think, “Well, I’ll just replace my old 150-horsepower unit with another 150-horsepower unit.” But modern compressors are way more efficient. If you don’t match your new system to your actual CFM requirements, you’re just burning cash on energy. It’s not a one-to-one swap anymore.

Jason Reed

Right, and we talked about this in our episode on right-sizing centrifugal compressors. Oversizing leads to short cycling, which is brutal on your equipment. You get more wear, more maintenance, and less reliability. It’s like buying a semi-truck to drive to the grocery store—just doesn’t make sense.

Lisa Saunders

And the thing is, plans change. You might think you’ll need more air in a year or two, but if that expansion doesn’t happen, you’re stuck with a system that’s too big for your needs. The smarter move is to buy what you need now, and add capacity later if you really need it. That’s what Henkel did—they worked with Kaishan’s distributor, right-sized their system, and ended up saving thousands in energy costs. Plus, they avoided millions in downtime. That’s real money, not just theoretical savings.

Jason Reed

Yeah, and that’s the value of working with someone who actually understands your application. Don’t just buy for the “what if.” Get a system audit, look at your actual demand, and size accordingly. You’ll save way more in the long run.

Lisa Saunders

Alright, so let’s get into maintenance and diagnostics—probably the area where people try to cut corners the most. Skimping on regular maintenance is just asking for trouble. You might save a little on labor or parts in the short term, but the risk of unplanned downtime, shortened equipment life, and even safety hazards is huge. I mean, unplanned downtime can cost thousands per minute in some industries.

Jason Reed

Yeah, and I’ve seen it firsthand. There was this maintenance team that thought they were being clever by skipping oil sampling—figured they’d save a few bucks and a little time. Well, guess what? They missed early signs of bearing wear, and the compressor failed right in the middle of peak production. The repair bill was massive, and the lost production? Don’t even get me started. That “savings” turned into a six-figure problem real quick.

Lisa Saunders

Oil sampling is one of those things that seems optional until it isn’t. It’s critical for catching issues like overheating or contamination before they become catastrophic. And for food-grade applications, you’re supposed to do it even more often. It’s not just about the compressor, either—it’s about protecting your whole operation.

Jason Reed

And, look, regular maintenance isn’t just about avoiding breakdowns. It’s about energy efficiency, equipment life, and safety. A well-maintained system runs better, lasts longer, and keeps your people safe. We’ve said it before, but it’s worth repeating—don’t try to save money by skipping the basics. It never works out in your favor.

Lisa Saunders

Yeah, and if you’re not sure where to start, talk to your local compressed air consultant. They’ve seen it all, and they can help you avoid these costly mistakes. That’s what we’re here for, right?

Jason Reed

Absolutely. Alright, that’s gonna do it for this episode of The Big Dog Podcast. If you’ve got questions or want to share your own “costly mistake” stories, hit us up. We’ll be back soon with more ways to keep your compressed air system running smarter, not harder. Lisa, always a pleasure.

Lisa Saunders

Thanks, Jason. And thanks to everyone listening. Don’t cut corners—cut costs the right way. See you next time on The Big Dog Podcast.