Top tips for increasing energy efficiency in pneumatic systems

Festo has recently published
Energy Efficiency at Festo, a new guide which details a number of ways for plant
managers to improve efficiency in their pneumatic production processes. The
guide provides detailed information about efficient technologies that will
ensure machines and systems consume fewer resources and less energy. Take the
time to search for possible approaches – it pays off.

Top tips to save the most
energy are:

1.Using energy
saving circuits, for example Festo’s OVEM closed loop vacuum generators,
monitor vacuum levels and only expend air when required, typical savings are

sizing of drives and tubing- reducing to the next smaller piston diameter can
decrease energy consumption by approximately 35%

switching line tube lengths – savings up to 25% can be achieved

circuits in standby or shutdown modes – eliminating flow of air in systems at a
standstill can provide savings of 20%

5.Reducing weight
and friction of moving elements has a major affect particularly on multi-axis
systems where initial over sizing becomes compounded – up to 18% energy saving can be realised

To download a copy of
EnergyEfficiency@Festo guidelines visit:

pneumatic applications can only be achieved with suitable compressed air
quality in accordance with ISO 8573-1:2010. Efficient
use of compressed air is an area where many manufacturing operations can make
considerable savings. It doesn’t have to be difficult, paying attention to a
few simple guidelines in the design and maintenance of pneumatic air
preparation systems can generate significant savings. Here are some measures which
promote quick and simple implementation in compressed air systems:

Whenever possible, switch off the air supply
during machine standstills, at the end of shifts, during breaks etc.

When higher pressure levels are required at
specific points within a network, use pressure boosters instead of increasing
pressure throughout the entire system

Pay attention
to the flow rates for air preparation units, over sized filter bowls will not function
optimally and won’t remove contaminants from the downstream system

Carefully check the need for filters, because
every filter stage reduces the flow rate and increases the pressure drop.
Follow the motto: “as much as necessary, as little as possible”.

Monitor filter
elements and change them before they lose efficiency and effectiveness. Clogged
filter elements reduce the flow rate through the air preparation unit and fail
to remove particulates. Up to50% of flow can be lost.

Install flow
meters. Flow meters allow you to monitor air consumption and changes with the
machine on and off, track trends and takeremedial action.

Use easy to
read pressure gauges. Gauges with preset operating zones enable fast setting
and checking of operating pressures without relying upon skilledtechnicians.

Fittings with modern sealing rings and
support functions ensure leak-proof, reusable connections.

Monitor all consumption. Countermeasures are only possible if you know
how much compressed air is used.

Energy Efficiency solutions from Festo

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