How to Identify Undersized Air Compressors Before They Cause Downtime

An undersized air compressor can quietly create serious problems within a compressed air system. While the system may appear to function normally at first, insufficient capacity can lead to pressure instability, equipment strain, and eventual downtime.

Identifying an undersized compressor early helps prevent production interruptions and costly repairs.

At Gordon Air Compressor, we frequently evaluate systems across Memphis and the Mid-South where compressors are struggling to meet demand.

What Does “Undersized” Mean?

A compressor is undersized when it cannot consistently supply the amount of compressed air required by the facility.

This often happens when operations grow, additional equipment is added, or the original system was not sized correctly.

Pressure Drops During Operation

One of the most common signs of an undersized system is pressure drop.

Facilities may notice tools losing power, equipment slowing down, or pressure gauges fluctuating during peak usage.

These issues occur because the compressor cannot keep up with demand.

Excessive Runtime

An undersized compressor often runs continuously in an attempt to maintain system pressure.

This leads to increased energy consumption, higher operating temperatures, and additional wear on internal components.

Compressors designed for intermittent use may struggle when forced to operate continuously.

Frequent Cycling in Some Systems

In systems with limited storage, undersized compressors may cycle frequently.

This means the compressor turns on and off repeatedly in short intervals, increasing wear on motors and electrical components.

Increasing System Pressure to Compensate

Operators may attempt to fix pressure issues by increasing system pressure settings.

While this may temporarily improve performance, it increases energy consumption, raises leak rates, and puts additional strain on equipment.

This approach does not solve the underlying problem.

Poor Equipment Performance

When air supply is insufficient, equipment performance suffers.

Tools may operate more slowly, automation systems may become inconsistent, and production efficiency may decline.

These issues can lead to reduced productivity and increased downtime.

Overheating and Equipment Stress

Compressors that are undersized often operate under constant strain.

This can lead to overheating, oil breakdown, increased friction, and eventual component failure.

Over time, this reduces the lifespan of the compressor.

Growth Without System Upgrades

Many facilities expand operations without upgrading their compressed air systems.

Additional equipment increases demand, but the original compressor may no longer be sufficient.

Regular system evaluations help ensure capacity keeps pace with growth.

How to Fix an Undersized System

Addressing an undersized compressor requires evaluating the entire system.

Solutions may include installing a larger compressor, adding a second unit, increasing storage capacity, or improving system efficiency.

In some cases, reducing leaks and optimizing system performance can help relieve demand on the compressor.

Preventing Downtime Through Proper Sizing

Proper sizing is essential for maintaining stable and efficient compressed air systems.

Identifying undersized equipment early helps prevent unexpected downtime, reduce maintenance costs, and improve overall performance.

A Balanced System Supports Reliability

Compressed air systems must be properly matched to the needs of the facility.

Ensuring that compressor capacity meets demand allows for stable pressure, reliable operation, and long-term efficiency.

For Memphis-area facilities, evaluating system capacity is one of the most important steps in preventing downtime and maintaining productivity.

We would love to help with your compressed air needs!

📞 901-327-1327
📍 706 Scott Street, Memphis, Tennessee 38112
📞 Emergency Service Available @ 901-482-5925