How to ensure that a compressed air system operates efficiently, reliably, and economically? This question is often asked by manufacturing companies, especially when installing new compressors or modernizing existing infrastructure.
We spoke with experts from the Baltic Diagnostic Service industrial equipment team – Project Manager Žilvinas and Service Manager Edgaras, who work daily with compressed air compressors and piping systems in various industrial facilities – from small workshops to large factories.
They share insights on why a compressor alone is not enough, which mistakes are the most costly, and how to design a compressed air system that helps save, not waste, energy.
Why is a compressor alone not enough?
Žilvinas: Clients often purchase a compressor and think that’s the whole solution. In fact, the compressor is just a part of the system. For compressed air to reach tools, production lines, or machines, a professional piping system is essential. Without it, even the best compressor can’t perform efficiently.
Edgaras: That’s why we don’t just install piping – we design the entire compressed air system from the compressor to the end-user point. This ensures efficient, safe, and long-lasting operation.
Why do you need compressed air pipelines at all?
Žilvinas: You can think of them as the “circulatory system” for your equipment. Whether you use a single machine or run a full factory – the pipeline directs air from the compressor to the user. It can be:
- a single air point in a workshop,
- multiple outlets in production or workshop areas,
- or a full mainline system along walls or ceilings with branches to each device.
Edgaras: It’s not just about pipes. It’s a complete system with dryers, filters, separators, receivers (air tanks), and solutions tailored to your real needs.
What components are necessary for an efficient system?
Edgaras: A typical system includes:
- A properly selected air compressor (piston, screw, oil-free scroll, etc.)
- Water separator
- Filters (to remove particles and oil residues)
- Air receiver with automatic condensate drain
- Dryer (refrigerated, adsorption, etc.)
- Piping sized for required pressure, distance, and air flow
Žilvinas: When needed, we also provide solutions for specific air purity classes – e.g., ISO 8573.1 / 1.4.1. If ultra-clean air is needed, we offer oil-free compressors.
Why does air quality affect equipment lifespan?
Edgaras: Poor air quality – moisture, oil, or dust – damages machine mechanisms and pneumatic systems. In the worst case – it leads to costly production stops.
Žilvinas: That’s why we ensure dryers work, the filtration system is correctly selected and installed, and condensate drains are automated. For clients in food, pharma, or automation sectors, this isn’t optional – it’s essential.
Can a poor pipeline really cause that much loss?
Žilvinas: Yes. Air loss is one of the most common issues. Improperly selected or poorly installed piping causes:
- pressure drops (every 1 bar loss increases costs by ~7%)
- limits equipment performance – if the required air doesn’t reach the machine
- speeds up wear and tear
Edgaras: That’s why we usually recommend reusable aluminum alloy pipes – they’re durable and easy to modify if the system needs changes. These are ideal for companies planning expansion.
What’s most important in system design?
Žilvinas: Design starts with a real-world analysis:
- how many shifts are working
- how many air consumers run at once
- distances between components
- needed receiver size
- whether an oil-free solution is required
Edgaras: A poorly tuned system means the compressor runs at full load, pressure fluctuates, and moisture builds up in pipes – all of which increase costs and reduce efficiency.
Does this investment really pay off?
Žilvinas: Absolutely. In some companies, compressed air accounts for up to 30% of total electricity use. Reducing pressure losses and having a more efficient compressor pays off within a few months.
What do you offer companies who want to check their system?
Edgaras: We can:
- perform an audit of the current system
- offer solutions for new projects
- consult on air purity requirements
- help select the optimal compressor with the full system
Why choose you?
Žilvinas: Because we don’t just “sit behind a computer.” We visit the site, evaluate actual air consumption, calculate pressure drops, distances, and assess the full system.
Edgaras: We install systems with certified aluminum piping that:
- are fire-resistant
- have better air flow than PVC or PPR
- use tight couplings – allowing easy expansion or changes
Žilvinas: Our team’s experience with large manufacturing and industrial companies ensures not only professional installation but also reliable maintenance and warranty support – so your equipment runs smoothly for years.
What do you recommend when buying larger compressors?
Edgaras: If installing a powerful compressor, it’s crucial to plan the entire system right away. This reduces operating costs, improves line performance, and extends equipment lifespan.
Want an efficient compressed air system?
Žilvinas: Contact us – we’ll not only install the system but also help you save, calculate efficiency, and avoid technical mistakes.
Edgaras: Call or write – we’ll find a solution tailored to your business needs.