COMPRESSED AIR, VACUUM, AND GENERATORS The connected compressor continues to evolve, reflecting a broader digital transformation taking place across manufacturing. While the concept of remote monitoring is not new, recent advances in AI, data analytics and automation are expanding what is possible - helping operators to better anticipate issues, respond faster and optimise their systems with greater accuracy. The next stage of compressor connectivity is being shaped by more sophisticated diagnostic tools. These systems can now interpret data from multiple sensors to identify deviations from normal operating conditions and recommend corrective action. Rather than simply notifying users that a fault has occurred, connected compressors are starting to provide a clearer picture of why a fault might happen, and how best to prevent it. The direction of travel is also towards greater interoperability. The growing use of open communication standards, such as OPC UA, has the potential to enable 34 HYDRAULICS & PNEUMATICS February 2026 www.hpmag.co.uk How data and AI are reshaping the next generation of connected compressors As digital technologies mature, the connected compressor is evolving from a simple monitored device into a source of strategic insight. Ben John* from Atlas Copco examines how advances in data analysis, automation and system integration are changing the way manufacturers manage performance, reliability and energy use. compressed-air systems to exchange data with wider factory networks - from production lines to energy-management platforms. Over time, these developments will deepen the role of compressed air within the Industrial Internet of Things, linking it more closely with factory-wide energy and production performance. From remote monitoring to asset management For manufacturers the most tangible progress so far has been the shift from isolated status alerts to a more unified view of compressed-air performance. Modern monitoring platforms bring together data from compressors, dryers and filters into a single dashboard, helping operators to move away from reactive service intervals and towards more informed, predictive maintenance planning. Connectivity is also improving collaboration between teams. Service histories, alarm logs and performance reports can be accessed remotely, ensuring engineers and plant managers are working from the same live data. This visibility not only streamlines maintenance but also strengthens accountability, allowing sites to demonstrate compliance with internal standards or external frameworks such as ISO 50001. Quantifying the benefits The operational benefits of connected compressor systems are starting to become clearer as more manufacturers experiment with data-driven maintenance. User feedback indicates that connected systems contribute to improved uptime, reduced running costs and more consistent air quality. Energy performance is another area of improvement. By analysing usage patterns, connected platforms can highlight air leaks, pressure losses and inefficient load cycles that would otherwise go unnoticed. Manufacturers using energy-management tools have reported savings of up to 30% through continuous optimisation and leakage detection, according to Atlas Copco data. For organisations operating multiple facilities, connectivity also opens the door to benchmarking. Comparing data between sites can identify where systems are performing efficiently and where further optimisation is possible. This in turn supports broader sustainability objectives by making energy performance measurable and transparent. AI in context: the human in the loop Artificial intelligence is beginning to play a growing role in how compressed-air systems are managed. By comparing operational data across similar installations, AI-based analysis can detect patterns and pinpoint potential risks earlier in the process. These insights are used to trigger maintenance actions or recommendations before a problem escalates. Yet despite these advances, human expertise remains central. Well trained and experienced engineers are essential in interpreting the data, validating the recommendations and deciding the
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