I fired up my 560 Saturday to smoke some ribs. When the charcoal is first lighting, there's a lot of smoke. And it shows how badly these things leak air...
Well the air and smoke has to go somewhere. I could argue that if it's coming out "all over" it's doing a good job of heating the entire grill (and ALL your food) evenly.
Folks have mentioned (even in this thread) sealing their machines better but I don't recall anyone saying it's saving them big money on fuel. Now you can add an oven type electric element so more cooking energy is coming from cheaper electricity, and even slow down the fan a little, and your hopper load will last longer. But you'll get less smoke flavor in your food too.
I'd say part of getting a gravity feed is recognizing fuel costs will be high. But this is not because the smoke leaks, it's because so much of the designed machine is getting hot that doesn't directly contribute to cooking your food. Plus they're parts that are pretty well convection cooled by ambient air. You don't want to kill yourself with the experiment but put a pellet grill in a cold garage and run it and then repeat the expt the next day with the gravity feed cooking the same food at the same temp for just as long. I think you'll find the gravity heats up the cold garage much better!
A classic offset smoker has the same issue. The part generating, and intercepting, the most heat is separated from the cook chamber. But at least there you can fairly easily add heat shields/reflectors, and even double-wall the firebox, to save on fuel consumption. After all, it's just a box. But few do that. The market for offsets just accepts you're going to use quite a few pounds of fuel to get the job done.
If someone can provide the cfm of the fan in these, we can do some precise calcs as to how much heat is being blown through these. From there, one could estimate maybe 10% could be saved by ensuring the smoke only follows the design path out the design ports/chimney, ie sealing those areas you see leaking. But I'm pretty sure you'll find it's a lot less than what's getting convected or radiated away from a gravity machine's
many hot surfaces. Heck even the chute at the tippy top needs the mesh finger guard so it must be getting hot!
IR radiation is huge from red hot coals. In a kettle, about half of that goes into cooking your food...your food "sees" the red coals. In a gravity machine those red coals are far removed from line-of-sight of your food. You just hope much of that heat gets blown by the fan into your cook chamber, again similar to the draft in a classic offset, but again, not very efficient.