Compressed air keeps production moving by powering cylinders, valves, blow-off applications, vacuum systems, tools, and many other parts of a manufacturing process.
Unfortunately, compressed air is easy to waste.
In many plants, air pressure is set higher than it needs to be. Over time, that higher pressure becomes the standard, leading to higher energy use, more air lost through leaks, and higher operating costs.
That is where SMC’s 4BAR Factory concept comes in.
In this blog, we will cover why plants often run at higher pressure than needed, what 4BAR Factory means, and which technologies can help support a lower-pressure, more efficient compressed air system.
Key Takeaways- Many plants use more compressed air pressure than their equipment actually requires. - High compressed air pressure can increase energy costs, air leakage, and total air consumption. - SMC’s 4BAR Factory concept focuses on reducing compressed air supply pressure to the level required by the equipment, with a target of 4 bar (58 PSI) where practical. - Compressed air pressure optimization starts with measuring air use, identifying pressure needs, and finding pressure loss. SMC offers products that support 4BAR Factory, including digital flow switches, pressure switches, filters, S Couplers, air-saving nozzles, impact blow products, booster regulators, high-power cylinders, vacuum units, speed controllers, and air management systems. |
Why Your Plant is Using Too Much Compressed Air | How Much Can You Save? | What Is SMC's 4BAR Factory | 3-Step Approach To Reduce Compressed Air Waste | Learn More About SMC's 4BAR Factory | Need Help? | Additional Resources | FAQ
Most plants do not waste compressed air intentionally. Compressed air waste builds up slowly and discretely over time.
A single machine needs more pressure, so the main air pressure is increased.
A filter becomes clogged, so the compressor pressure is raised to make up for the pressure drop.
A leak is ignored because production is still running.
An air blow application uses continuous air because no one has reviewed whether a better nozzle or pulse blow setup could do the same job with less air.
These issues can make the entire compressed air system work harder than it needs to.
If one machine needs higher pressure, the easy fix is often to raise the main compressed air pressure for the entire facility. That may help the problem machine, but it also sends higher pressure to every other machine, valve, cylinder, blow gun, and air line in the plant.
The better approach is to ask: does the whole compressed air system need more pressure, or does one area need a local air boost?
Think of compressed air like water flowing through a pipe. The compressor creates air pressure, but that pressure has to travel through filters, tubing, fittings, valves, couplers, and other components before it reaches the machine. Along the way, some pressure is lost.
For example, your compressor may be supplying 100 PSI, but because of restrictions in the system, a machine might only receive 85 PSI.
Common causes of compressed air pressure loss include:
- Clogged Or Restrictive Filters
- Undersized Tubing
- Poor Fittings
- Inefficient Couplers
- Long Piping Runs
- Valves With Limited Flow
- Poorly Selected Nozzles Or Blow Devices
When that happens, many plants respond by increasing compressor pressure so the machine gets the pressure it needs. The machine may work better, but now the entire compressed air system is running at a higher pressure.
Leaks are another common source of compressed air waste. Over time, fittings can loosen from vibration, seals and O-rings can wear out, hoses can crack or become damaged, and threaded connections may no longer seal properly. Leaks can also develop around valves, cylinders, quick-connect couplers, and other pneumatic components as equipment ages.
A small leak may not seem serious, but the compressor still has to produce the air that escapes. And when system pressure is turned up higher to compensate, even more air can escape through the same leak.
Air blow applications use compressed air that is directed through a nozzle, tube, blow gun, or valve to perform a specific task on a product, machine, or work area, such as:
- Cleaning parts or equipment
- Drying products after washing or processing
- Cooling components during production
- Removing chips, shavings, or machining debris
- Removing dust or contaminants
- Separating parts on conveyors or assembly lines
- Ejecting products from tooling or fixtures
- Moving lightweight materials
As important as air blowing can be, it is one of the most common areas for compressed air waste.
Air blow processes use large volumes and a continuous flow of compressed air for tasks that do not require continuous flow. Open tubes, poorly selected nozzles, and oversized blow-off systems can also consume far more compressed air than necessary.
Since compressed air is expensive to generate, every cubic foot of unnecessary air flow increases energy consumption and operating costs. In many cases, the issue is not that the application needs more air pressure—it is that the air is being delivered inefficiently
4BAR Factory is a concept by SMC that focuses on reducing factory air pressure to the level actually needed by the equipment. The target is 4 bar, or 58 PSI, where practical.
But 4BAR Factory does NOT mean every machine in every plant can instantly run at 4 bar (58 PSI). It also does not mean reducing pressure without checking machine performance. Instead, 4BAR Factory is about using the right compressed air pressure in the right place, instead of using more pressure everywhere.
SMC’s 4BAR Factory approach looks at the full compressed air system and asks:
- How much compressed air is being used?
- Which machines need which pressure?
- Where is compressed air pressure being lost?
- Which applications use the most air?
- How much air is being used during standby?
- Where can air leaks be reduced?
- Which blow-off applications can be improved?
- Where is local pressure or extra actuator force still needed?
- How should future machines be designed for lower-pressure operation?
The short answer: up to 29% in compressed air energy costs, depending on your system and operating conditions.
That 29% figure is based on SMC’s 4BAR Factory concept, which focuses on reducing compressed air supply pressure from 7 bar (100PSI) to 4 bar (58 PSI) where practical (more on that below). Actual savings will vary based on your facility, current pressure settings, compressor operation, air demand, equipment design, duty cycle, and electricity rate.
Compressed air often represents about 10% of a typical industrial facility’s electricity use, and in some facilities, it can reach 30% or more (source: Energy Star). That means compressed air pressure optimization can be a major opportunity for plants trying to reduce energy use and operating costs.
The table below shows estimated annual compressed air energy costs by facility type, along with the possible savings if compressed air energy use is reduced by 29%.
|
Facility Size/Type |
Rough Annual Compressed Air Energy Cost |
Estimated 4BAR Factory Energy Savings At 29% |
|
Small shop or light manufacturing facility |
$5,000–$25,000+ per year |
$1,450–$7,250+ per year |
|
Mid-size manufacturing facility |
$25,000–$100,000+ per year |
$7,250–$29,000+ per year |
|
Large manufacturing plant |
$100,000–$500,000+ per year |
$29,000–$145,000+ per year |
|
Very large, air-intensive facility |
$500,000+ per year |
$145,000+ per year |
These are industry estimates only and should be used as a general planning guide, not a guaranteed savings calculation.
For many manufacturers, even a modest reduction in compressed air pressure can translate into meaningful energy savings over time. The key is ensuring that equipment continues to operate reliably at the lower pressure.
To help manufacturers systematically reduce compressed air energy consumption, SMC has broken the process down into three practical steps. Rather than simply lowering pressure and hoping for the best, this approach focuses on understanding air usage, optimizing the system, and then validating performance to ensure reliable operation.
Before a plant can reduce compressed air pressure, it needs to understand how air is being used.
This includes measuring:
- Total compressed air consumption
- Pressure demand by machine
- High-flow areas
- Standby air consumption
- Pressure changes during machine operation
- Pressure loss between the compressor and point of use
To gather this information, it may be necessary to install temporary flow meters, pressure sensors, or other measurement technologies at key locations in the system. Measurements are typically taken at the compressor, along main distribution lines, and near critical machines to identify where pressure drops occur. It is also helpful to collect data during normal production, shift changes, and idle periods so the team can see how air demand changes throughout the day.
The result: Instead of guessing which areas can run at lower pressure, the team can review actual compressed air usage and identify the equipment that truly requires higher pressure, and the equipment that doesn’t.
After air use is measured, the next step is to optimize line pressure.
This may include:
- Reducing pressure loss
- Replacing restrictive components
- Improving air blow efficiency
- Preventing air leaks
- Confirming machine operation at lower pressure
- Using local pressure or local power increases where needed
In practice, this often means inspecting filters, regulators, dryers, hoses, fittings, and valves for restrictions that create unnecessary pressure drop. Facilities may also perform leak surveys using ultrasonic leak detectors, replace inefficient air nozzles with better alternatives, and test machines at gradually lower pressures to determine their actual operating requirements.
The goal is to avoid using high compressor pressure as a blanket fix for local machine issues.
For example, if one application needs more force, it may be better to use a high-power cylinder or local booster regulator instead of raising pressure across the entire plant.
Once air use is understood and line pressure issues are addressed, the plant can review compressor pressure. The goal is to reduce compressor pressure to the level required by the equipment. In some cases, a facility may also be able to stop using high-pressure compressors that are no longer needed.
A common approach is to lower the compressor pressure setpoint in small increments while monitoring machine performance, production quality, and pressure at critical points of use. If equipment continues to operate reliably, the pressure can often be reduced further. Any machines that experience issues can then be evaluated individually rather than increasing pressure for the entire facility.
For new machines or plant upgrades, this step can also help set a lower-pressure standard for future pneumatic systems.
Ready to see what a lower-pressure, more energy-efficient compressed air system could look like in your facility?
Compressed air pressure optimization starts with understanding how your system is performing today.
We can help you:
- Measure compressed air flow, pressure, and consumption
- Identify pressure losses and high-use applications
- Evaluate compressed air leaks and standby air usage
- Review opportunities to reduce compressed air pressure
- Assess air blow applications and air-saving technologies
- Develop a practical roadmap toward a 4BAR Factory approach
- Select the right SMC products to support your goals
Whether you're just beginning to investigate compressed air energy savings or you're ready to implement a plant-wide pressure optimization strategy, our team can guide you through every step of the process.
Contact us today to schedule a compressed air assessment or discuss your 4BAR Factory opportunities.
Read More Articles about Omron
FAQ |
What Is SMC’s 4BAR Factory For Compressed Air Pressure Optimization?SMC’s 4BAR Factory is a compressed air pressure optimization concept that helps manufacturers reduce factory air pressure to the level actually needed by their equipment. The target is 4 bar, or 0.4 MPa, where practical. The approach focuses on measuring compressed air use, reducing pressure loss, improving pneumatic efficiency, and using local pressure support where machines still need extra force or higher pressure.Does SMC’s 4BAR Factory Mean Every Machine Runs At 4 Bar?No. SMC’s 4BAR Factory does not mean every machine in the plant must run at 4 bar. The goal is to understand actual compressed air pressure requirements and reduce pressure where possible. Some machines may still need local pressure boosting, higher-force cylinders, or other pneumatic components to maintain performance while the overall compressed air system operates more efficiently.
Why Does Lower Compressed Air Pressure Save Energy?Lower compressed air pressure can save energy because compressors usually require more electrical power to produce higher pressure. When a plant runs at higher pressure than needed, it can increase energy use, air leakage, and total compressed air consumption. Reducing compressed air pressure where practical can help lower energy costs while still supporting reliable machine operation.
Will Lower Compressed Air Pressure Hurt Machine Performance?Lower compressed air pressure should not hurt machine performance when the system is reviewed properly. A 4BAR Factory approach uses flow measurement, pressure monitoring, pressure loss reduction, air-saving components, and local pressure or local power increases where needed. The goal is to reduce wasted compressed air without starving machines of the pressure, flow, or force they need to operate correctly.
What SMC Products Support 4BAR Factory And Compressed Air Energy Savings?SMC products that support 4BAR Factory include digital flow switches, digital pressure switches, compressed air preparation filters, S Couplers, air-saving nozzles, impact blow guns, impact blow valves, pulse blow units, high-power cylinders, booster regulators, vacuum units, precision regulators, air-saving speed controllers, and air management systems. These products help facilities measure compressed air use, reduce pressure loss, improve air blow efficiency, lower standby air consumption, and provide local pressure support where needed.
How Can I Tell If My Plant Is Using Too Much Compressed Air?A plant may be using too much compressed air if system pressure is set higher than most machines require, leaks are common, air blow applications run continuously, pressure drops occur across the system, or machines use air during standby. The best place to start is by measuring compressed air flow and pressure at key points in the plant. This helps identify high-use machines, pressure loss, air leaks, and applications where air-saving improvements may make sense.
Where Should A Plant Start With Compressed Air Pressure Optimization?A plant should start compressed air pressure optimization by measuring current air pressure, air flow, machine demand, standby air consumption, and pressure drops. From there, the team can identify where compressed air is being wasted and decide whether lower pressure, better components, leak reduction, air-saving nozzles, local pressure boosting, or an air management system could help improve efficiency. |