In a case study, we successfully reduced energy consumption by 28%, simply by fine-tuning the pressure in our compressed air systems. This approach shows that energy efficiency can be improved without costly upgrades to machinery. 

Reducing energy costs is key to sustainable manufacturing.  

High energy costs in industrial manufacturing don’t have to be a given. By optimising existing systems – without investing in new equipment – you can achieve significant energy savings.  

In a case study, we successfully reduced energy consumption by 28%, simply by fine-tuning the pressure in our compressed air systems. This approach shows that energy efficiency can be improved without costly upgrades to machinery. 

Why is high air pressure a problem? 
In many industrial environments, the working pressure of pneumatic systems has been historically set higher than necessary. While 7.5 bar is a common standard, this often leads to excessive energy consumption at the compressor. According to SMC data, reducing the pressure by just 1 bar can lead to energy savings of up to 8%. Maintaining high air pressure means higher energy costs for air compression, which has a significant impact on operational efficiency. 

SMC’s solution was simple: optimise the pressure throughout the site to a more efficient level. 

Step-by-step pressure optimisation: A controlled, risk-free approach 
We adopted a methodical and safe approach to pressure optimisation. Over six months, supply pressure was gradually reduced by 0.1 bar in stages. This controlled process allowed us to monitor the system’s stability and ensure there were no negative impacts on production.  

Additionally, we optimise specific areas of the air system by using strategically placed pressure boosters, allowing localise pressure increase for applications requiring higher air pressure (such as vacuum systems, blowers, and some actuators). This ensured overall system pressure could be reduced without compromising performance at critical points. 

Factory Concept

Results: Energy savings and efficiency improvements 

After the optimisation was complete, the results were clear: 

  • Working pressure: The original working pressure was 7.5 bar. After the reduction, the pressure was optimise to 6.0 bar, a 1.5 bar decrease; 

  • Energy consumption: Before optimisation, the energy required to produce 1 m³ of compressed air was 0.121 kWh. After optimisation, this dropped to 0.087 kWh, representing a 28% reduction in energy consumption; 

  • No need for equipment modification: Unlike other approaches that often require changes to machinery or new equipment, our solution involved no alterations to the existing machines. The optimisation focused on adjusting pressure levels and enhancing air system efficiency; 

  • Impact on productivity: Throughout the entire optimisation process, we saw no reduction in machine performance or productivity. 

These energy savings not only helped reduce operating costs but also extended the lifespan of system components, reduced leakage losses, and enhanced overall operational stability. Pressure reduction can also offer improvements in terms of operator safety. 

Advantages of reducing air pressure in pneumatic systems 

  • Energy savings: Reducing pressure by just 1 bar can save up to 8% in energy; 

  • Lower operating costs: Immediate reduction in energy consumption directly impacts operational expenses; 

  • Longer equipment lifespan: Proper pressure optimisation reduces wear on components, helping to extend their service life; 

  • Lower CO₂ emissions: Decreased energy consumption translates into reduced greenhouse gas emissions. 

Contact SMC today, our experts can help you optimise your compressed air system and realise real savings