Compressed air systems and inspections

Effective compressed air system inspections with a CMMS system are based on automation and technical precision. Instead of ad hoc repairs, the system schedules regular leak checks and timely filter replacement based on actual component wear. By centralizing data, the CMMS allows for the quick identification of leaks and points of reduced flow capacity , which often require unnecessary system pressure increases.

Maintaining full valve efficiency allows for a safe reduction in operating pressure. A reduction of just 1 bar on machinery allows for a similar reduction in compressor performance. This translates to approximately 6-8% energy savings. Digital scheduling eliminates human error, ensuring the stability of technical indicators and a longer service life of the entire industrial infrastructure.

Conscious control of compressed air systems

Considering that electricity alone accounts for 65% to 85% of the entire process costs, ensuring optimization and regular maintenance is essential. It’s important to constantly monitor compressor operating parameters , as unnecessarily high pressure can significantly drain company budgets. Continuous monitoring allows for early detection of such errors.

Consciously managing these settings allows for precise adjustments to equipment operation to actual production demands at any given time. In the long run, this translates into noticeably lower energy bills and a longer, more stable machine lifespan.

What are the consequences of leaks in installations?

Leaks are a major cause of losses in pneumatic systems. Research suggests that between 5% and 60% of energy production (depending on the facility) is lost due to faults. Leaks audible to the human ear are only a fraction—most small leaks generate only waves in the ultrasonic range (38-42 kHz). Therefore, maintenance schedules configured in the CMMS system allow for preventive loss prevention.

What leak points need to be verified during the inspection?

When planning inspections, leaks should be divided into those occurring in supply lines and those occurring on machines. By implementing standardized electronic checklists , we ensure that the main leakage points are regularly verified:

• threaded, plug-in, glued and welded connections,
• air preparation stations (e.g. cracked filter glasses, damaged membranes),
• distribution valves and worn seals of moving parts,
• piston rod actuators (blow-through between chambers).

Power lines are easier to diagnose without powering down, but their repair requires planned production shutdowns. Leaks on machinery are more difficult to detect but easier to repair.

How to estimate losses using the pressure drop method?

One of the most effective ways to diagnose the condition of a network during an inspection is by measuring pressure drop . When given a measurement task, the technician follows a consistent, repeatable procedure:

• disconnects all receivers from the network so that they do not distort the results,
• generates working pressure in the system,
• turns off the compressors and completely cuts off the power supply to the valve.

It then records the initial and final pressure at a precisely defined time (preventing it from dropping below 20% of the operating pressure). Knowing the total volume of pipes and tanks from the software database, air leakage is automatically calculated, providing a precise picture of the leak’s scale.

Energy consumption analysis method

Another effective method for assessing leak tightness is measuring the energy consumption of compressors when production machinery is shut down. After the network is filled to operating pressure, the time and energy used solely for refilling leaks (between subsequent starts) are measured. This method requires knowledge of the compressors’ efficiency. While it may be less precise with large hysteresis in operating pressure , systematically entering this data into the CMMS application creates a measurable reporting database. This allows for long-term assessment of the system’s condition, permanently supporting planned preventative measures .

The use of compressed air at Cedrob plants

At Cedrob plants, compressed air is crucial to automated lines. It powers actuators, valves, and grippers in portioning, thermal processing, and packaging machines, ensuring rapid and repeatable operation. Pneumatic technology is widely preferred in the meat industry because it ensures safety in a highly humid environment. Maintaining rigorous hygiene is equally crucial. Before main cleaning, air blowing systems remove raw material residue from hard-to-reach machine crevices.

Maintaining this infrastructure requires precise planning, which is facilitated at Cedrob plants by a CMMS system. This software replaces distributed spreadsheets with a centralized database and mobile app, enabling immediate fault reporting and easy ordering of spare parts. Thanks to CMMS, the maintenance department can base its work on continuous prevention, efficiently scheduling compressed air system inspections, effectively preventing breakdowns and costly downtime.

How does reducing losses in pneumatic systems increase a plant’s competitiveness?

The shift from reactive measures to consistent prevention, tightly integrated with CMMS system analytics, is the foundation for sustainable optimization. Regular ultrasonic leak audits and precise pressure drop mapping enable early fault detection, effectively protecting the budget from hidden losses. The reliable implementation of digital procedures and constant infrastructure monitoring create a data-driven work environment in the maintenance department. As a result, intelligent pneumatic network management ensures the continuity of automated production, supports the highest hygiene standards, and directly translates into increased competitiveness and profitability for the entire enterprise.