Optimising industrial processes with advanced pneumatic control solutions

21 May, 2025

When managed correctly, pneumatic control systems can provide solutions to some of the most pressing challenges facing industry today. However, the key is moving beyond outdated approaches and adopting more efficient, reliable, and smarter systems.

The first step is addressing the common issue of energy inefficiency. Compressed air systems are known for being energy-intensive, with some estimates suggesting they account for up to 30% of a plant’s total energy consumption. Yet, many businesses continue to operate with systems that waste significant amounts of energy. One of the simplest but most effective solutions is improving pressure regulation. Too often, systems operate at higher pressures than necessary, which leads to wasted energy. By adjusting the pressure to match the specific needs of each task, businesses can reduce their overall energy usage.

Variable speed drives (VSDs) in compressors have become another critical development. Traditionally, compressors run at full speed regardless of demand. VSDs, on the other hand, adjust the speed of the compressor according to the amount of air required. This ensures that energy isn’t wasted by over-producing compressed air when demand is low. For UK manufacturers, where rising energy costs are a constant concern, these technologies offer a straightforward way to reduce operating costs.

Addressing air leaks and system maintenance is equally important. Leaks are common in older systems, yet many companies fail to spot them until they’ve caused a significant increase in energy usage. Regular inspections, combined with the use of modern leak detection technology, can quickly pinpoint these issues. Simple fixes, like replacing seals or tightening fittings, can prevent air from escaping and improve efficiency. Over time, this can lead to substantial savings.

Reliability

Alongside energy savings, improving the reliability of pneumatic systems is vital. Downtime due to system failures can be costly, particularly in industries where productivity is closely tied to machine uptime. In the UK, sectors like automotive manufacturing, food production, and packaging all rely heavily on pneumatic systems to maintain consistent production schedules. The cost of unplanned downtime isn’t just financial; it also affects reputation, deadlines, and customer satisfaction.

Fortunately, advances in technology are making it easier to predict when systems will fail, rather than reacting to problems after the fact. Predictive maintenance, powered by sensors and data analytics, has become a game-changer. Modern pneumatic systems can now monitor themselves in real time, flagging potential issues before they disrupt production. For example, sensors can detect subtle changes in pressure or temperature that might indicate a problem with a valve or compressor. This allows engineers to address issues proactively, reducing both downtime and repair costs.