Process, Controls & Plant Focus on: Compressed Air 24 | Plant & Works Engineering www.pwemag.co.uk Annual Buyers’ Guide 2026 In today’s industrial landscape, where energy costs continue to escalate and environmental sustainability becomes increasingly critical, the optimisation of compressed air systems has evolved from a maintenance consideration to a strategic business imperative. Companies that master this optimisation can achieve significant competitive advantages through reduced operational costs, improved equipment reliability, and enhanced environmental performance. Understanding true energy impact Every pressure decision in a compressed air system carries an energy impact across the entire facility. Even reducing operating pressure by just 0.1 to 0.2 bar can deliver measurable energy reductions while easing mechanical stress on system components. This sensitivity makes precise optimisation essential. Compressed air becomes increasingly expensive as pressure rises because energy demand grows disproportionately with higher pressure. Operating above actual requirements means paying for unused capacity, a cost that compounds in multi-shift industrial environments. Studies show that lowering system pressure by 1 bar can yield significant energy reductions. For example, a 10-bar compressor typically delivers 15–20% less flow than an 8-bar unit due to transmission ratio or motor-speed differences. In large facilities with multiple compressors and extensive piping, these savings can add up to hundreds of thousands of dollars per year. The impact isn’t limited to energy use: higher pressures accelerate wear across the entire system, increasing maintenance needs, shortening equipment life, and driving up total operating costs. Pressure optimisation therefore delivers both immediate and long-term benefits. Understanding industrial compressed air demand patterns Modern industrial facilities exhibit complex compressed air demand patterns that vary significantly throughout operational cycles. Peak demand periods may require maximum system capacity, while off-peak times operate at substantially lower requirements. Traditional system designs often size equipment for peak demand scenarios, resulting in inefficient operation during the operating hours when demand is lower. Advanced system optimisation considers these demand patterns and implements staged compression strategies, variable speed drive technology, and intelligent control systems that adapt to real-time requirements. This approach ensures that compressed air generation matches actual consumption patterns, eliminating the waste associated with constant high-pressure operation regardless of actual demand. The sophistication of modern manufacturing processes also means that different areas of a facility may have varying pressure requirements. Some applications may function effectively at 56 bar, while others require the full 8-bar standard. System optimisation can incorporate pressure reduction valves and zone-specific pressure management to ensure each application receives appropriate pressure without over-pressurizing the entire network. The customer expectation paradox Industrial customers naturally seek assurance in their compressed air investments, driven by the critical role these systems play in production continuity. This desire for security often manifests as a preference for higher operating pressures and oversized equipment, driven by the logical assumption that greater pressure provides greater reserve capacity and operational reliability. The appeal is understandable: higher numbers suggest the appearance of additional compressed air reserve – hence, better performance, increased capability, and protection against unexpected demand spikes. This preference is particularly pronounced in Italian markets where industrial traditions and past experiences with former technology continue to influence purchasing decisions. Historical experiences with reciprocating compressors, which operate effectively at higher pressures, sometimes carry forward to modern screw compressor applications where the optimal operating parameters are different. However, actual operational requirements tell a different story. Most industrial applications require approximately 6 bar of working pressure—a standard that effectively serves the majority of pneumatic tools, automation equipment, and process applications. This pressure level has been established through decades of equipment development and represents the optimal balance between performance and efficiency for most industrial applications. The gap between what customers believe they need and what their applications actually require represents both a challenge and an opportunity for system optimisation. Customers often express concerns about having “enough” compressed air, leading to specifications that exceed actual requirements by significant margins. This over-specification creates ongoing operational inefficiencies that compound over the system’s operational lifetime. This expectation-reality divide extends beyond pressure requirements to the overall system design philosophy. Customers often focus on individual components—particularly compressor specifications—while the true performance drivers lie in system integration: receiver tank sizing and placement, distribution network design, pressure regulation throughout the facility, and intelligent control systems that optimise performance across varying demand conditions. Bridging expectation and efficiency Compressed air specialists face the complex task of delivering both customer confidence and operational efficiency. This requires translating customer expectations into optimised system designs that exceed performance requirements while minimising energy consumption and operational costs. The The efficiency paradox Compressed air systems represent one of the most significant energy consumers in industrial facilities, often accounting for 10-15% of total electricity consumption across manufacturing sectors. Yet within these systems lies the tremendous potential for optimisation - potential that goes far beyond simply selecting the right compressor or upgrading to higher-capacity equipment. The path to maximum efficiency requires understanding the intricate relationship between pressure settings, system design, receiver tank configuration, distribution networks, and actual operational requirements. Niccolò Casini, Senior Director, Product Management, ELGi Europe, explains further.
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