TECHNOLOGY FOCUS Operations & efficiency
Pros and cons of compressed air reduction: Advantages: Can reduce compressor energy consumption • Helps compensate for oversized components in older systems • Reduces leakage losses Disadvantages: May require larger, more expensive components • Does not guarantee lower air consumption • Can impact system performance
turbulent flow conditions can all increase energy consumption. Positioning valves closer to actuators, optimising pipe diameters and avoiding unnecessary bends or restrictions can significantly improve compressed air system performance.
10. Evaluate the risks of system-wide pressure reduction Lowering pressure across an entire
compressed air network can deliver savings at the compressor level, but it also reduces the system’s ability to handle peak demand. If not carefully managed, this can lead to pressure drops, reduced performance and even unplanned downtime.
network design. Addressing leaks directly is often more effective than relying on pressure reduction alone.
9. Optimise pipework design to minimise energy losses Inefficiencies are not limited to components. Long pipe runs, large dead volumes and
The key takeaway is that compressed air optimisation cannot be reduced to a single variable. Decisions about pressure must be considered alongside component sizing, application requirements and overall system design.
Even broader technology choices should be evaluated carefully. For example, replacing pneumatic actuators with electric alternatives is not always the most efficient solution. In
some cases, pneumatic systems offer advantages such as lower weight and reduced energy use during static holding, particularly in end-of-arm tooling applications.
In practice, achieving the right balance requires
robust engineering support and the ability to model real operating conditions. Festo provides a range of sizing, simulation and configuration tools that allow engineers and machine builders to evaluate different scenarios. Available online, these tools make it easier to compare pressure levels, component sizes, cycle times and energy consumption before a machine is built. They also help identify where pressure reduction will deliver genuine savings, and where it may introduce inefficiencies or performance risks. Combining application knowledge with data- driven design tools allows system designers to make informed decisions at both component and system level: optimising not just compressed air usage, but overall machine performance, cost and sustainability.
Festo
www.festo.com/gb/en
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automationmagazine.co.uk
Automation | July/August 2026
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