How to get your air compressor ready for winter

In this article, we’ll explain the main risks, give you a practical winter checklist, and show how proactive maintenance can save energy and extend the life of your compressed air equipment.

The risks of winter for air compressors

When temperatures drop near or below freezing, compressed air systems face unique challenges:

• Frozen condensate can block pipes, drains, and filters, leading to downtime.
• Thickened oil reduces lubrication, putting strain on moving parts.
• Moisture can freeze and expand in lines, causing leaks to worsen.
• Cold starts make compressors harder to start, stressing motors.

With compressed air making up a significant share of industrial energy use, avoiding inefficiency and downtime is critical. That’s why winter readiness is as much about cost and energy savings as it is about protection.

Drain and manage condensate

Moisture is unavoidable in compressed air systems, but in winter it poses a serious risk. Condensate can freeze inside receivers, filters, and lines, causing blockages or even ruptures.

• Manual drains should be checked and emptied frequently.
• Automatic zero-loss drains are a safer option, as they continually discharge moisture without wasting compressed air.
• If your drains are outdoors, protect them with insulation or heat trace tape.

Locate and repair leaks

Leaks are costly at any time of year, but in cold weather they worsen as moisture freezes and expands around weak points. Even small leaks can cause significant pressure drops and wasted energy.

• Conduct a thorough system inspection before winter.
• Repair audible leaks straight away, but don’t ignore smaller ones—they often account for most of the waste.
• Consider a professional compressed air audit to pinpoint hidden leaks.

Fixing leaks not only avoids winter damage but also cuts energy use, improving efficiency.

Maintain and replace air filters

Frozen or clogged filters restrict airflow, reduce efficiency, and can even shut down equipment. In winter, saturated filters are especially vulnerable to freezing.

• Check filters regularly and drain condensate where needed.
• Replace filter elements at least annually, or sooner if they show signs of blockage.
• Clean filters improve air purity, reduce pressure drops, and lower energy consumption.

Check and change lubricants

Lubricating oil thickens at low temperatures, which reduces its ability to protect moving parts. This can lead to excess wear and harder cold starts.

• Switch to synthetic lubricants in winter. They resist thickening and flow more consistently.
• Always follow manufacturer guidance on oil grade and change intervals.
• Monitor oil levels closely, as low temperatures can mask issues.

Insulate and protect exposed lines

Any outdoor or unprotected pipework is at high risk in winter. Frozen lines can block airflow, damage components, and disrupt production.

• Insulate external lines with foam rubber, fiberglass, or foam glass.
• Use trace heating for added protection in very low temperatures.
• Check intake vents and inlets to ensure snow, rain, or ice cannot enter and cause blockages.

For sites with complex layouts or external plant rooms, our specialist builds team can help design tailored protection.

Keep compressors warm

If your compressor house gets too cold, oil thickens, condensate freezes, and components may fail to start.

• Seal draughts and insulate compressor rooms.
• Install cabinet heaters to keep lubricants above minimum temperature.
• Use ambient heaters in compressor houses to prevent cold starts and premature wear.

Consider heat recovery for efficiency

Compressors generate large amounts of heat, and in winter that heat can be put to good use.

• Duct hot air back into the compressor room to keep ambient temperatures stable.
• Use recovered heat for space heating or pre-heating process water.
• A well-designed system can recover up to 90–94% of input energy, reducing both heating costs and carbon footprint.

For more detail on the ins-and-outs of heat recovery, take a look at our full article on air compressor heat recovery.

Seasonal shutdown tips

If your site reduces production or shuts down over the Christmas and New Year period, take extra precautions:

• Drain all condensate from receivers and lines before shutdown.
• Power down or disconnect heaters and trace tape safely.
• Carry out preventative maintenance—winter downtime is an ideal opportunity for inspections, filter changes, and repairs.
• When restarting, check oil, filters, and drains carefully before bringing systems back online.

Schedule regular servicing and inspections

Professional servicing is one of the best safeguards against winter breakdowns. Experienced engineers can spot vulnerabilities before they turn into costly failures.

At Maziak, we provide comprehensive compressed air servicing and maintenance to keep your system reliable and efficient year-round.

Winter can be tough on compressed air systems, but with the right preparation you can avoid frozen lines, costly breakdowns, and wasted energy. From condensate management to heat recovery, every step you take now pays off in uptime, efficiency, and peace of mind.

If you’d like advice on preparing your compressor for winter—or to book a service—our team is here to help!

FAQs

Why is winter preparation important for air compressors?

Cold weather can cause condensate to freeze, lubricants to thicken, and lines to block, all of which lead to downtime and costly repairs.

How often should I drain condensate in winter?

Manual drains should be checked daily in freezing conditions. Automatic zero-loss drains are more reliable and save time.

What oil is best for cold weather?

Synthetic lubricants are ideal as they flow better at low temperatures and reduce cold-start stress on moving parts.

Can heat recovery really save money in winter?

Yes - up to 90–94% of compressor input energy can be recovered and reused for space heating or process water, cutting energy bills.

What should I do if my site shuts down for Christmas?

Drain all condensate, protect exposed lines, and carry out preventative maintenance before shutdown. On restart, check oil, filters, and drains carefully.