www.hpmag.co.uk HYDRAULICS & PNEUMATICS February 2026 35 appropriate response. This collaboration between human judgement and algorithmic analysis ensures that decisions remain grounded in operational context - an essential safeguard in critical industrial environments. This interplay between automation and experience mirrors the aspirational principles of Industry 5.0, where technology will enable maintenance engineers to focus on diagnosis and strategy rather than reactive firefighting, and ensure that service interventions are based on evidence, not assumption. Towards an interoperable future Looking ahead, the potential of compressor connectivity will depend on how successfully it integrates with wider manufacturing systems. The move towards open communication protocols such as OPC UA is an important step in that direction, creating the foundations for greater interoperability between different types of equipment. In an integrated environment, compressed-air systems could one day coordinate dynamically with other utilities and production assets - adjusting performance in response to real-time demand, or sharing data with buildingmanagement and energy-monitoring platforms. While this level of automation remains some way off for most manufacturers, the trajectory is clear: connectivity is shifting from being a convenience to an enabler of continuous improvement. At the same time, data from connected machines is feeding back into product development and service planning. Insights into how compressors perform under varying load conditions and environments are helping manufacturers refine designs, improve reliability and tailor service packages more precisely to customer needs. Balancing reliability and resilience Ultimately, the goal of connectivity is to strengthen operational resilience. The ability to identify anomalies early, respond quickly and measure the impact of interventions is transforming how maintenance teams operate day to day. Additionally, real time system performance insights, are enabling companies to unlock energy savings through services such as leak detection, central control, energy recovery, and heat pumps; which can help reduce their operating costs, and carbon footprint in line with Science Based Targets. As more systems become connected, reliability will increasingly depend on visibility. The real value lies not in the volume of data collected, but in how effectively it is interpreted and acted upon. When maintenance moves from reaction to prediction, downtime becomes the exception rather than the norm. This evolution is gradual rather than revolutionary - but its direction is unmistakable. Connectivity is reshaping the culture of maintenance, helping manufacturers move towards a more analytical, collaborative and sustainable approach to managing their compressedair systems. The next phase of compressor connectivity The shift towards connected compressors is not a leap into automation but an incremental journey of insight and refinement. As analytics, AI and integration technologies mature, manufacturers are beginning to unlock new layers of efficiency, reliability and transparency from their compressed-air systems. While challenges remain - from data integration to user adoption - the direction is set. The connected compressor is becoming an indispensable component of industrial digitalisation, offering the visibility and intelligence needed to build more resilient operations in an unpredictable world. Real-world results from remote monitoring Preventing damage before it happens An early alert identified a rise in moisture levels within a rotary-screw compressor - a sign of potential condensation build-up that, if left unchecked, could have led to mechanical damage and production loss. Engineers were able to investigate remotely, confirm the issue and carry out preventive maintenance before any harm occurred, keeping the system running without interruption. Avoiding downtime Temperature readings from one installation showed a steady upward trend that could easily have gone unnoticed during normal operation. Thanks to continuous monitoring, the anomaly was flagged early and traced to restricted airflow around the cooling system. A simple on-site clean and oil top-up restored performance, avoiding what could have become a costly breakdown. Two problems solved in one visit In another case, irregularities in both pressure and temperature readings prompted a detailed remote analysis. The data suggested separate sensor and cooling issues - both of which were addressed in a single service visit. By combining interventions, the site avoided multiple stoppages and reduced overall maintenance time. Maintaining service continuity during restrictions During the pandemic, remote monitoring proved vital in maintaining business continuity. With limited site access, service engineers were able to review live operational data off-site, identify risks and guide on-site teams through necessary adjustments. This proactive approach kept compressed-air systems safe and compliant, even when in-person inspections were not possible. *Ben John, Business Line Manager, Compressor Technique Service, Atlas Copco Compressors UK
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