But I did notice one thing this year ��� many companies are pushing electric and mechanical options more so than ever, noting that they���re moving away from compressed air and pneumatic control because of efficiency issues. Even legacy pneumatics companies had a big push for their electric solutions.

At Festo, they were showing a canning/packaging machine from Codi Manufacturing that was converted from all-pneumatic control to almost completely electric, apart from the vacuum grippers used to place the four-pack cardboard holders onto the cans. (Stay tuned for a full story on this machine in a later issue).

Mike Hoffman, manager of enginieerinig from Codi said the need for quick changeovers and less downtime was the initial reason behind the push to move to electric actuation. But when they saw that the actions were more controlled, had less violent motions, and were more efficient, it was a no-brainer to remove the pneumatic valves.

Over at Coesia, a manufacturer of packaging machinery, I had a chance to view several machines running both pneumatic and electric control systems. There, they switched one of their main compressed air systems to a vacuum pump because, once again, compressed air leakage and inefficiency were a concern. (Again, stay tuned for more information on Coesia���s systems.)

This seems to be a recurring theme lately. Clearly, there has been a noticeable shift in industrial and automation technologies in recent years, with electric actuation steadily replacing pneumatics in various applications. Should we be concerned about pneumatics becoming obsolete?

No. And here���s why: just like hydraulics, pneumatic technologies still have cost-effectiveness, durability, and density on their side.

As I was drafting this commentary, I just happened to stumble upon a live LinkedIn presentation by Dr. Elvira Rakova, CEO at DIREKTIN, which offers a platform to reduce energy consumption of compressed air systems. She admitted that yes, in certain circumstances, electric actuators are the way to go, especially when multiple velocities and cycles are required. But when looking at long-term costs and maintenance, pneumatics will almost always win out as the less costly option and the one that���s easier and cheaper to maintain and fix.

The caveat here, she said, is in sizing and selection. It is crucial to right-size your components, particularly your cylinders, to ensure an efficient operating system. It���s just as crucial to maintain and manage these systems with modern technology. Compressed air is still a cheap commodity, but if it���s not monitored and used wisely, it could cost you thousands of dollars more than necessary.

While the transition to electric systems offers undeniable advantages, it is crucial to recognize that pneumatic technologies still hold their own, offering unique benefits and cost-effectiveness that cannot be easily dismissed. 窪蹋勛圖 systems are inherently simple and robust. They can withstand some of the harshest environments, such as washdown and high-speed, repeatable processes, which can cause vibration and damage electric actuators. Sometimes, they are the only option where electrical spark or flammable risks are present.

Throughout our October issue, and in every issue of Fluid Power World, you will find several articles highlighting opportunities to increase compressed air efficiency, manage leakage, and right-size your system components. Be sure to turn to read this Design Notes item from CaseIZ and Rockwell, as well as others to learn how to optimize your compressed air and automation systems. And as always, visit for new content each week.

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If you have ever done leakage detection with an ultrasonic leak detector you will get to know the common leak locations. If you have no detector, there is no excuse these days, excellent equipment is available for you to purchase at a reasonable price, go get it!

A common sight ��� or rather sound ��� is finding leaking hoses that connect to hand tools and blow wands. Red rubber hose is very commonly used in industrial plants and shops, sometimes thousands of these hoses are present, with many leaking in various spots, all usually due to poor installation or wear.

It is very common to find tools installed with fittings that have no thread sealant. It is very important to ensure that steel connectors have sealant applied to stop air leaks. Fig. 1 shows an example. This fitting has likely been leaking from day one, and over time, due to the constant stresses from daily tool use, the fittings have become loose, causing a significant leak flow.

Fig. 2 shows another common problem, the use of old-style crimped connections. These connectors often damage the hose on installation and will loosen as the hose end gets worn from constant use. These connectors and similar screw type bands can become damaged and start to leak if production machinery like forklifts drive over them, distorting the connector. These days push lock connectors and high quality hose are being used in plants that follow Best Practices.

Another common leak location is the quick connect couplers at the end of each hose or the hose itself though pinholes that develop if the hose is damaged or melted due to welding slag.

Keep an eye out for hose and connector leaks. Ensure your hoses are installed correctly.

泭

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When is it time to retire a compressor? Your old unit may have served you very well over the last few decades, reliably providing a seemingly endless supply of compressed air. Some units, like the unit in Fig. 1, have been around so long that they have almost become part the family.

This design is extremely hardy and tough ��� they last a long time and were well designed for longevity. In fact, this unit could well last another 10 to 15 years if maintenance is kept up. However, there are hidden costs that must be defined by measuring the compressor���s performance. The unit in the picture, while efficient at full load, has a tough time supplying part loads. And this is a problem at this site because the average loading is only about 30% of the compressor���s capacity.

This 150-hp unit, and many like it, is running in a mode called ���straight modulation,��� the least efficient way to control lubricated screw compressors at part load. When the pressure rises above the compressor setpoint, a control signal causes the inlet valve to start to choke off the flow. Typical energy reduction for this type of control is about 3% for every 10% reduction in flow, which becomes problematic if the compressor is lightly loaded.

This particular compressor does not follow the typical curve; its energy reduction is almost zero for any reduction in flow output. It constantly consumes power of about 125 kW when running at 190 cfm or at 650 cfm. Its specific power (kilowatts per 100 cfm) is often near 70 kW/100 (normal is about 18 kW/100 cfm for a well-controlled compressor).

If left running the way it is, its annual operating cost would be about $100,000 per year in supplying about 200 cfm of average compressed air flow. But should a new compressor with better part load control (called load/unload) be installed in its place, the operating costs would be reduced to about $50,000 per year. And if a new VSD compressor was purchased, the electrical cost would reduce to about $29,000 per annum!

For this plant, the operating staff must decide: waste more than $710,000 in electricity over the next 10 years or replace the unit with a new more efficient unit? The choice seems clear once we bring out the hidden energy costs.

Are you keeping an old unit running that should be retired? How much could you save if the compressor was replaced?

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