22/07/2026
Large-scale compressed air transformation is not just a piping replacement activity.
It starts with understanding the existing network, identifying hidden energy losses, checking leakage levels, and then planning the right upgrade without affecting production.
In this case, a 25-year-old GI compressed air network across 12 production lines and 3 buildings was assessed. The system showed 34% air leakage, while the operating pressure was set at 10 bar even though the highest actual requirement was only 7 bar.
The upgrade approach included replacing the old GI network with aluminium modular piping, converting 14 dead-end runs into a balanced ring main system, and improving compressor control through lead-lag sequencing across five compressors.
Two old compressors were decommissioned, dryers were added on active compressor lines, and the system was redesigned for better pressure stability, lower leakage, and improved energy efficiency.
A properly planned compressed air overhaul can reduce losses, improve reliability, and support long-term plant performance.