Insight August/September 2025 www.pwemag.co.uk Plant & Works Engineering | 11 compressor system can operate at a reduced air pressure, not only can the local pressures be reduced but it’s possible to reduce the whole network pressure. Compressor systems may be optimised for a given pressure/flow demand and this must be considered. Lower network pressures mean less losses from leaks. Air networks need to be able to cope with peak demands and fluctuations, educing pressures and the peak flow capacity whilst potentially saving energy could cause pressure drops and lost production. Positive, pressure reduction can reduce energy consumption and CO2 It helps to compensate oversizing. If the pressure level at the output of the compressor is reduced, less electrical energy is needed. Air leakage is smaller when pressure is reduced. The backstroke pressure can be reduced, if no/less load needs to be moved. In green field applications, a reduction of energy consumption can be reached. But all components needs to be optimised for the lower pressure. Negative, pressure reduction causes different problems A well sized cylinder needs to be one size larger when pressure is reduced from 6 to 4 bar. A well sized 6 bar cylinder needs the same amount of air as a well sized 4 bar cylinder. All other components (Fittings, Tubes, Valves, Air preparation, …) also needs to be bigger. There is a need for more construction space. Larger components are in general more expensive than smaller. Most vacuum generators have their best evacuation time to reach a defined vacuum at 6 bar. In brown field applications the system needs to be analysed in detail, if a pressure reduction makes sense. Whole machine approach The best approach is to engage with specialist applications engineers that can support machine optimisation according to all your priorities – machine performance, build costs, lifetime costs, energy efficiency etc. We would also strongly recommend looking at the whole solution not just one function at a time. Even narrowing the discussion down to replacing air actuators with electric drives can be a false generalisation. For example, does it make sense to use a sophisticated electric gripper on the end of a pick and place system, if a pneumatic one can do the job? Unlike electric grippers, pneumatic grippers do not consume energy when exerting a constant force gripping a component. In most cases you can save 50-60% of the mass. This is critical at the ‘end-of-arm as it enables you to reduce the size of all the supporting actuators – rotary, X-Y and Z. The savings on the overall system can be dramatic in purchase and operating costs. The recommendation is to focus on what you want to achieve and let specialists such as Festo support you in the configuration of your machine. For further information please visit: https://www.festo.com/gb/en/PWE
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