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Compressed Air in the Manufacturing Industries

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Compressed Air in the Manufacturing Industries

Compressed air is a kind of essential resource in the area of manufacturing, often regarded as the "fourth utility" alongside electricity, water, and gas. Compressed air is versatile enough to power a wide range of machinery and tools, making it indispensable in a variety of processes.



In this post, we will focus on the application of compressed air in the manufacturing industries,  the various types of air compressors used and how to design a air compresson system.


Key Applications of Compressed Air in Manufacturing

Powering Pneumatic Tools and Equipment

Compressed air powers many types of manufacturing equipment:


  • Pneumatic Robots: In manufacturing process, the use of pneumatic robots is a common phenomenon. They rely on compressed air to run smoothly and efficiently on production lines.

  • Pneumatic tools: Tools such as screwdrivers, nail guns and impact spanners use compressed air to carry out assembly work faster and with better control.

  • Plasma cutting and welding: Compressed air supports these processes by maintaining a clean, stable environment that ensures precise cutting and welding.

Material Handling and Conveying

Efficient material handling is vital in manufacturing:


  • Vacuum Lifters: These lifters use compressed air to safely move heavy or fragile materials without causing damage.

  • Pneumatic Conveyor Systems: Compressed air-driven conveyors ensure a steady flow of raw materials or products, which is critical for continuous production.


Painting and Finishing Processes

Compressed air enhances the quality of finishing tasks:


  • Spray Painting Equipment: It atomizes the paint, ensuring a smooth and even coating for aesthetic and protective purposes.


Cooling and Cleaning Processes

Cooling and cleaning are key to smooth operations during the manufacturing process:


  • Cooling Machined Parts and Tools: Compressed air rapidly cools down tools and parts during or after operation to prevent damage.

  • Air Blasting for Cleaning: Used to blast surfaces to remove debris or prepare them for further processing.


Packaging and Labeling

Compressed air ensures precision and speed in packaging lines:


  • Sealing, Labeling, and Packaging Machines: These machines rely on compressed air to operate smoothly, maintaining high-speed packaging without compromising quality.


Plastic Manufacturing Processes

Compressed air plays a critical role in shaping plastic products:


  • Blow Molding, Thermoforming, Injection Molding, and Extrusion: Compressed air is used to mold, shape, and finish plastic components efficiently.


Other Applications

Several other processes benefit from compressed air:


  • Filter Pulsing in Dust Collectors: It helps clear dust from filters, extending their life and improving performance.

  • Air Curtains: These maintain clean areas and regulate temperatures by creating a barrier of air.

  • Fermentation Processes (Sparging): Compressed air bubbles are introduced into liquids to aid mixing and proper chemical reactions, particularly in food and beverage manufacturing.


Types of air compressors used for Manufacturing Application

Rotary Screw Compressors

  • Overview: Rotary screw compressors are prevalent in manufacturing due to their efficiency and capability to provide continuous compressed air.

  • Functionality: They work by trapping air between two meshed rotors, compressing it as the rotors turn.

  • Applications: Ideal for industries needing a constant air supply, like automotive and packaging.

    Screw Air Compressor Used in Manufacturing Industries



    High Efficiency Permanent Magnetic Screw Air Compressor 

Reciprocating Piston Compressors


  • Overview: These compressors use pistons driven by a crankshaft to deliver gases at high pressure.

  • Functionality: The air is compressed by the upward movement of the piston in the cylinder.

  • Applications: Best suited for smaller, demand-driven operations and intermittent use, commonly found in workshops and construction sites.


Centrifugal Compressors

  • Overview: Centrifugal compressors are also known as radial compressors, which are dynamic and work by converting kinetic energy into potential energy through a rotor.

  • Functionality: Air enters the compressor at the center of a spinning impeller and is propelled outward by centrifugal force, increasing its velocity.

  • Applications: Used in large manufacturing facilities like chemical plants where high volume and high-pressure air are needed.


Rotary Vane Compressors

  • Overview: Rotary vane compressors are known for their compact size and reliability.

  • Functionality: These compressors have a slotted rotor with varied blade placement that revolves in a stator cavity to compress the air.

  • Applications: Commonly used in woodworking, dry cleaning, and automotive repair shops.

scroll air compressor

Scroll Compressors

  • Overview: Known for their quiet operation and reliability, scroll compressors offer oil-free air compression.

  • Functionality: It consists of two interleaved spirals that move eccentrically to trap and compress the air.

  • Applications: Ideal for medical applications, laboratory settings, and pharmaceutical manufacturing where clean, oil-free air is critical.


Designing a Compressed Air System for Manufacturing industries


Determining Requirements for compressed air

  • Calculating CFM and PSI needs: Determine the total air flow (CFM) and pressure (PSI) required by all the equipment and processes that will use compressed air.

  • Assessing peak and average air demand: Identify the peak air demand during the busiest production periods and the average demand during normal operations. This helps in sizing the compressors and storage tanks appropriately.

Selecting Energy-Efficient Compressors and Components

  • Variable Speed Drive (VSD) compressors: VSD compressors adjust their speed to match the air demand, resulting in significant energy savings during periods of low demand.

  • Proper sizing of compressors and storage tanks: Oversize or undersize compressors and storage tanks can lead to energy waste and inefficient operation. Work with compressed air experts to select the optimal sizes based on your facility's requirements.


Ensuring Reliability of the System

  • Backup compressors: Install backup compressors that can take over in case of a primary compressor failure. This helps prevent production interruptions.

  • Contingency plans: Develop contingency plans for various scenarios, such as power outages or equipment breakdowns. Regular maintenance and having critical spare parts on hand can minimize downtime.


Maintaining Air Quality

  • Choose the right filters and dryers: Select filters and dryers based on the specific air quality requirements of your applications. For example, oil-free compressors and high-efficiency particulate air (HEPA) filters may be necessary for certain processes.

  • Meet industry standards and regulations: Ensure that your compressed air system complies with relevant industry standards and regulations, such as ISO 8573-1 for air quality classes.


Planning for Future Growth and Expansion

  • Expandability of the compressed air system**: Design the system with flexibility in mind so that new compressors, storage tanks, and transmission pipelines can be easily added as the facility's needs grow.

  • Accommodate new equipment and increased demand**: Plan for potential increases in air demand as a result of new production lines, equipment upgrades or facility expansions. Make sure your compressed air system can handle these changes without sacrificing performance or efficiency.




Compressed air is vital in manufacturing, essential for everything from powering tools to ensuring product quality. This blog has highlighted key areas including determining air requirements, selecting efficient compressors, ensuring reliability, maintaining air quality, and planning for future growth.


 If you're looking for a reliable and efficient air compression system, contact Aivyter today. Our team of experts is ready to provide you with tailored solutions that meet your specific needs. Let us assist you in improving your manufacturing capabilities to the next level.

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