PNEUMATICS 26 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Compressed air is a vital utility in British industry. Yet like any industrial system, pneumatic infrastructure requires ongoing care if it is to remain efficient and reliable. Valves, filters, regulators and distribution lines are subject to wear over time, and if maintenance is overlooked the result can be higher energy consumption, reduced performance and unexpected downtime. The maintenance of pneumatic systems presents a distinct challenge. Unlike mechanical breakdowns that can be seen or heard immediately, pneumatic losses are often invisible. A small leak in an airline may not be audible on a noisy shop floor, yet over the course of a year it can waste a significant volume of compressed air. Similarly, a valve that has started to stick or a filter that is slowly clogging will not necessarily trigger alarms until production quality suffers. The hidden nature of these issues means that many businesses only respond when problems become acute. A more deliberate approach is required if compressed air systems are to operate efficiently and reliably. One practical solution is to establish a structured programme of preventive maintenance. Rather than waiting for failures, engineers can schedule checks on common weak points. Filters should be inspected regularly and replaced before they reach the point of restriction. Regulators and lubricators should be examined to ensure that they are functioning within their specified ranges. Actuators should be observed to confirm smooth movement. Even simple activities such as tightening fittings can prevent avoidable leaks. Preventive maintenance requires time and discipline, but the costs are small when compared with the energy wasted by leaks or the production losses caused by sudden failures. The unpredictable While preventive maintenance deals with predictable wear, monitoring technologies can address the unpredictable. Advances in sensors now make it possible to track airflow, pressure and humidity in real time. These devices can be placed at strategic points in a network to provide visibility of system behaviour. A sudden drop in pressure at one branch may indicate a developing leak, while a gradual increase in flow through a filter may signal impending blockage. By collecting this data, maintenance teams can intervene at the right moment, replacing parts only when they genuinely need attention. This predictive approach avoids both unnecessary component changes and disruptive breakdowns. The adoption of such monitoring is not uniform across industry. Larger facilities with high energy bills are often quick to invest because the return is measurable. Smaller sites may hesitate, perceiving sensors and data systems as complex or expensive. However, costs have fallen in recent years and the devices are now more accessible. Wireless communication also means that retrofitting to existing plant is less intrusive. For many businesses the initial outlay is offset within a short period through energy savings alone. By quantifying leakage and inefficiency, managers are given the evidence needed to prioritise corrective work. Training is another important factor. Maintaining pneumatic systems is often less visible than other plant priorities. Proactive care, supported by monitoring technologies and staff training, can cut energy waste, reduce downtime and extend equipment life. Taking a structured approach helps industry unlock both financial and environmental benefits. H&P reports. Practical steps to ensure pneumatic systems remain reliable
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