TECHNOLOGY FOCUS Operations & efficiency
HIGHER OR LOWER? TEN WAYS TO ACHIEVE
COMPRESSED AIR OPTIMISATION Nick Hartwell, Senior
Application Engineer at Festo, busts some myths and offers
expert guidance
on getting the most out of compressed air systems
M
ost businesses today recognise that reducing energy consumption is both environmentally responsible
and commercially beneficial. In compressed air systems, lowering system pressure has long been seen as a straightforward way to achieve these savings. For many engineers, the logic is simple: lower pressure equals lower energy use. However, the reality is far more complex. Compressed air is used for far more than simply driving pneumatic cylinders. Across industrial automation, it powers a wide variety of equipment, including vacuum generators, nozzles and suction cups, as well as air knives, air blasts and blow guns. Each of these applications operates under different requirements in terms of pressure, flow and performance, and each respond differently to changes in supply conditions. As a result, compressed air optimisation is not about applying a single rule. It involves understanding how pressure interacts with system design, component sizing and application demands. Here are ten key considerations every machine builder and automation engineer should keep in mind. 1. Don’t assume lower pressure will reduce energy consumption Reducing system pressure is often promoted as a universal energy-saving measure. While it can reduce compressor energy demand, this does not automatically translate into lower overall air consumption at the machine level. In our experience, total consumption can remain unchanged – or even increase – depending on how the system is configured and sized. 2. Identify where older machines can benefit from pressure reduction
24 July/August 2026 | Automation
Many legacy machines were designed when energy costs were less of a concern. As a result, pneumatic components were frequently oversized as a safety margin. In these cases, reducing operating pressure can help eliminate built-in inefficiencies and deliver measurable energy savings without compromising performance.
3. Consider whether higher pressure is more efficient for new machines In contrast, modern machines are typically engineered with greater precision. Components are selected and sized to meet exact performance requirements. Reducing pressure in these systems can require larger actuators and increased airflow to maintain performance, potentially offsetting any expected energy and cost savings. 4. Account for larger component sizing at lower pressures A reduction from 6 bar to 4 bar may appear modest, but it has considerable design consequences. To achieve the same force output (force = pressure × area), it requires larger cylinder bores and tubing diameters to ensure adequate flow. This not only increases costs but also enlarges the machine’s footprint and moving mass. These aspects can directly affect dynamic performance.
5. Recognise that larger low-pressure
systems don’t always use less air A common misconception is that lower
pressure inherently reduces air usage. In reality, a correctly sized cylinder operating at 6 bar can consume the same amount of air as a larger cylinder operating at 4 bar. The perceived savings may therefore be negligible once the entire system is considered. 6. Understand how vacuum applications respond to pressure changes Vacuum generation introduces additional complexity. Many vacuum generators are optimised to achieve maximum vacuum at around 4 bar. Increasing pressure beyond this point does not improve vacuum level but it does increase flow rate, reducing evacuation time. A useful way to think about this is as a trade-off between cycle time and air consumption.
7. Optimise air jets and blow systems to reduce hidden consumption
While cylinders tend to receive the most attention, other compressed air equipment – such as air knives, blow guns and ejectors – can be major energy consumers. In many applications, compressed air usage can be optimised through improved nozzle design, local pressure regulation (often down to around 2 bar) or short, controlled pulses rather than continuous flow.
8. Address leaks directly rather than relying on pressure reduction alone Reducing pressure can help minimise
compressed air system losses, as lower pressure reduces the volume of air escaping through leaks. However, focusing solely on pressure ignores other critical factors, such as system integrity, maintenance practices and
automationmagazine.co.uk
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