Focus on: Compressed Air Process, Controls & Plant February/March 2026 www.pwemag.co.uk Plant & Works Engineering | 21 improve efficiency and reduce emissions. We’re getting involved much earlier in the design phase of new plants to ensure the most efficient technology is built in from the start. Carbon capture is still relatively young, but interest is accelerating. In the next five to ten years, I expect strong uptake among high energy users - steelworks, car plants, and large manufacturers - who need reliable ways to cut emissions. The technology exists; it’s now about applying it at scale and integrating it effectively into industrial processes. PWE: What’s driving demand for nitrogen and oxygen generation in particular? Are you seeing new applications emerge? CH: It comes down to cost, control, and confidence. Many UK manufacturers already use nitrogen and oxygen in some form, but they’re realising that generating their own supply can deliver savings and operational stability. When customers move from bulk delivery to on-site generation, they gain independence from regional pricing differences and transport logistics. We do a lot of work helping customers understand what purity they actually need. For years, many were supplied with the highest purity simply because that’s how bulk systems work. But if their process doesn’t demand it, they can save energy by producing only what’s required. That’s where our role becomes more consultative - helping customers understand their own applications first, then matching the right technology to it. PWE: When it comes to engineered air and gas systems, what are the main technical challenges or integration issues customers face? CH: The biggest challenge is often cultural rather than technical. Many sites have operated the same way for decades, and change takes education and trust. Customers need to feel confident that on-site systems will deliver what’s promised, particularly when purity or pressure is critical. Technically, integration is about understanding the whole process - pressure levels, flow requirements, and how different systems interact. Every bar of pressure adds roughly 7% to energy use, so there’s growing interest in reducing system pressures where possible. That’s leading to new project work across all three pillars of AGA - industrial gases, high pressure, and low pressure - as customers look for smarter, more efficient solutions. PWE: How are advances in digitalisation or remote monitoring influencing how these systems are designed, commissioned, and maintained? CH: Remote monitoring is becoming fundamental. Customers increasingly want installations that run hands-free - systems that just work. Of course, all rotating equipment carries some risk of failure, but by using digital monitoring we can spot trends, anticipate problems, and plan maintenance before downtime occurs. It’s a move from reactive to predictive service. For customers, that means fewer disruptions, better energy performance, and lower maintenance costs over the life of the equipment. For us, it’s also a feedback loop - the more data we gather, the more insight we gain to improve future designs. 3. Reliability, sustainability, and lifecycle thinking PWE: How are air and gas systems evolving to improve total cost of ownership? CH: The focus has shifted from capital cost to lifecycle cost. Over a ten-year period, maintenance can represent up to 80% of total ownership cost, depending on the product. If we can reduce unplanned service interventions and extend component life, that’s where customers really see the benefit. Remote monitoring helps by reducing failures and improving efficiency. Lower service frequency means lower cost and less waste. It’s all about providing predictable performance - giving customers confidence in uptime and long-term reliability. PWE: Energy recovery and efficiency are recurring themes in industrial operations. Where do you see the biggest untapped opportunities in air and gas processes? CH: Energy management systems are key. If we can control how and when compressors and gas systems perform, we can optimise energy use and extend machine life. The relationship between control, efficiency, and wear is often underestimated. By managing load cycles more intelligently, we reduce both energy consumption and carbon footprint. Many customers still run at higher pressures than necessary. Lowering that pressure by even one bar can save around 7% in energy. Those
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