Saving Energy & Extending Equipment Life: How Extended-Surface Pleated Filters Pay Off in Louisville Facilities

Every facility manager in Louisville knows the struggle: energy bills that creep up every season, HVAC units that seem to work harder each year, and maintenance costs that eat into budgets. One of the simplest and most effective fixes we’ve seen isn’t a system overhaul—it’s upgrading to extended-surface pleated filters.

At Precise Air Filters, we’ve helped local warehouses, offices, and healthcare buildings extend the life of their HVAC equipment and reduce operating costs with these filters. Here’s how the change pays off.

Real Results From Louisville Facilities

Our local clients have seen consistent improvements after switching to extended-surface pleated filters.

• A manufacturing facility in Jeffersontown reduced its HVAC energy use by 11 percent after replacing standard flat filters with 4-inch extended-surface pleated filters.
• An East End medical building reported fewer maintenance calls and a 15 percent increase in airflow across its main rooftop units, verified during quarterly service checks.
• A downtown office complex that had been changing filters every 30 days now gets close to 60 days of use per filter cycle, cutting both labor and material costs.

These results aren’t isolated—they reflect how proper filtration design directly affects system efficiency and lifespan.

The Engineering Behind the Savings

According to ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers) guidelines, filter selection has a direct impact on pressure drop, airflow, and fan energy.

1. Lower Pressure Drop

Extended-surface filters have more pleats per square inch, giving air more paths through the filter media. That larger surface area reduces the initial pressure drop—so fans don’t have to work as hard to move air.

2. Better Airflow Consistency

When air moves evenly through the system, it prevents the buildup of hot and cold spots in buildings. Balanced airflow also protects sensitive components such as coils and heat exchangers from dust accumulation, which can otherwise lead to overheating or freezing issues.

3. Higher Dust-Holding Capacity

The pleated design increases media area by up to 300 percent compared to a flat filter. That means it captures more airborne particles before airflow resistance rises, allowing longer service intervals and fewer filter changes—without sacrificing air quality.

In short: extended-surface filters maintain efficiency longer and reduce total HVAC strain.

The Cost of Ignoring Filter Efficiency

Many older commercial systems in Louisville were designed decades ago, when filter efficiency wasn’t a priority. Running those systems with outdated filters leads to:

• Higher fan energy consumption (as the system compensates for clogged filters)
• Premature motor wear due to increased resistance
  Dirty coils that trap moisture and reduce heat transfer efficiency
• Inconsistent air quality, especially in large shared workspaces

Replacing a fan motor or coil can cost thousands. Investing in better filtration—often just a few dollars more per unit—prevents that expense.

Case Study: Downtown Office HVAC Upgrade

One of our Louisville clients, a six-story office building near Fourth Street, used standard 2-inch filters for years. The building’s facilities team complained of high static pressure readings and uneven cooling between floors.

After upgrading to extended-surface pleated filters with a MERV 11 rating, we measured:

• A 0.25-inch drop in system pressure immediately after installation
• A 9 percent reduction in blower energy consumption (based on meter data over 60 days)
• More stable airflow across all floors, confirmed by balancing tests

The building now replaces filters every two months instead of every four weeks, saving labor and materials while maintaining better comfort conditions.

Backed by Industry Authority

The performance benefits of pleated filters are well documented by ASHRAE Standard 52.2 and publications from the U.S. Department of Energy. Both highlight that maintaining clean airflow paths and minimizing resistance are key to HVAC efficiency and longevity.

Our recommended products, such as the Multi-Pleat XL8 and DP-Green Extended Surface Series, meet or exceed these standards. Each features moisture-resistant frames and synthetic media engineered for durability in Louisville’s variable humidity.

Trusted by Louisville’s Facility Managers

Our clients choose extended-surface pleated filters not only for the technical performance but for the long-term payoff: lower operating costs, cleaner systems, and healthier air for employees and tenants.

If your HVAC system is showing signs of strain—rising energy bills, uneven air distribution, or frequent coil cleaning—it may be time to evaluate your filters.



Contact Precise Air Filters today to schedule a site assessment and find the right extended-surface pleated filter for your facility.