Compressed Air Systems from A to Z: We Design and Install
Is the compressor running, but there is still insufficient pressure at the workstations? Does pneumatic equipment lose power when several units are operating at the same time? In such cases, the problem may lie not in the compressor, but in the compressed air distribution system.
Incorrectly sized pipework, long routes, a poorly planned layout or leaking connections increase pressure losses. As a result, the compressor has to work harder, energy consumption rises and equipment does not receive the required airflow.
Hidrobalt takes care of the entire process – from assessing the current situation and air demand to system design, component selection and installation.
When the compressor alone is not enough
The compressor generates compressed air, but the pipework must deliver it efficiently to every point of use. As air moves through the network, it meets resistance, so every additional metre of pipe, bend or incorrectly selected fitting can affect the final pressure.
If the pipework is too narrow, the route is excessively long or the system has been expanded without considering the additional air demand, equipment located further away may not receive sufficient airflow. Simply increasing the compressor pressure does not eliminate the cause – it only increases the compressor load and electricity consumption.
Where does pressure loss usually occur?
The efficiency of a compressed air system is most commonly reduced by:
- an undersized pipe diameter that restricts airflow;
- long or inefficiently routed pipework that increases resistance;
- an excessive number of bends, transitions and branches;
- leaking connections through which compressed air is continuously lost;
- failure to allow for future expansion, leaving the existing pipework unable to meet increased demand.
The system should therefore be designed around the actual requirements of the equipment and future development plans, rather than the current premises layout alone.
An efficient system starts with an accurate assessment of demand
Before designing the system, we assess how much compressed air is required at each workstation, the operating pressure needed by the equipment and how many air consumers may operate simultaneously.
We also consider distances from the compressor room, possible pipework routes, the premises layout and planned changes to production. Based on this information, we select the correct pipe diameters and plan the main lines, branches and connection points.
A well-prepared design helps avoid costly corrections after installation and ensures that the required airflow reaches every workstation.
Why do we use Prevost PPS pipework?
For compressed air systems, we use modular Prevost PPS aluminium pipework. Its pipes and fittings are made from 100% aluminium, making them lightweight, corrosion-resistant and suitable for long-term operation.
The smooth internal surface helps reduce resistance and maintain efficient airflow. Since aluminium does not rust, rust particles cannot accumulate inside the pipework and enter the compressed air or connected equipment.
The modular design allows the system to be installed quickly and adapted more easily as requirements change. New branches can be added, connection points relocated or the pipework extended without a complex reconstruction of the entire system.
One partner for the entire process
There is no need to coordinate system design, component supply and installation separately. Hidrobalt provides:
- needs analysis and consultation;
- system design and preparation of drawings;
- pipe sizing and component selection;
- assembly using original Prevost components;
- pipework installation;
- system expansion and technical support.
We can install a new compressed air system or assess an existing one and recommend how it could be improved or adapted to increased demand.
What are the benefits for your business?
Professionally designed and installed pipework helps maintain more stable pressure at points of use, reduce air losses and make more efficient use of the compressed air generated by the compressor.
A modular system also makes it easier to respond to changes – relocate equipment, add new connection points or expand production without replacing the entire pipework network.
Are you planning a new compressed air system, or is your existing system no longer providing the required pressure? Contact us – we will assess the situation and propose a solution tailored to your company’s needs.
