The critical role of air preparation units in pneumatic system performance
Pneumatic systems rely on air preparation units (FRL units) as essential components for proper function. By delivering optimal quality compressed air, these units boost the efficiency and lifespan of pneumatic components while significantly reducing downtime.
Standard air treatment components
An air treatment unit or air preparation unit generally includes at least these components:
Additional elements like residual pressure relief valves, soft start-up valves, membrane air dryers or pressure switches can be included, depending on the application.
Thanks to their modular design, SMC systems can be configured to suit particular industrial requirements, all while preserving compact and efficient layouts.
Why use a compressed air treatment unit?
Compressed air produced by compressors frequently carries impurities such as debris, oil, and moisture, which can reduce the performance and durability of pneumatic systems. In addition, particles may enter the system due to pipeline erosion.
Frequent issues resulting from contaminated compressed air:
- Deterioration of lubrication
- Blockage of passages or pilot holes
- Failure to start under low-temperature conditions (freezing)
- Internal mechanical malfunctions
- Formation of water inside the system
- Pressure losses, blocked filters and auto drains becoming stuck
- Leaks caused by damaged seals
- Decrease in product quality, especially in processes such as painting, blowing, printing, etc.
Contaminated compressed air can also affect automation components, leading to issues such as:
- Valve and actuator malfunctions due to grease washout
- Auto drains seizing as a result of rust inside the ducts
- Air leaks caused by damaged seals
- Corrosion in regulators
- System saturation due to excess moisture
Solution: Air preparation units (FRL units) ensure compressed air is supplied in optimal condition by:
- Removing particles, moisture and oil
- Adjusting pressure according to system requirements
- Adding lubrication to the air to protect pneumatic components
By ensuring proper air quality, these units improve equipment performance, prevent system failures and increase process efficiency in industrial applications.
How to choose the appropriate air preparation unit?
Selecting the right air treatment FRL unit involves carefully considering several factors:
- Specific application: The air quality needed differs depending on the application. With our air treatment guide, you can identify the right air quality class for your application and select the products that best match it.
- Important factors to assess when selecting a maintenance unit:
- What connection size is needed? It is advisable to determine the needed peak flow. Calculate the peak flow with our flow rate calculation software and size the components of the maintenance unit based on the results.
- Is a pressure relief valve required? It is advisable to install one so the machine can be pressurised or depressurised, for instance during industrial maintenance.
- Is pressure regulation necessary? A pressure regulator is generally essential to adjust the network pressure to the optimal level for your equipment. This can be done manually or remotely using electro-pneumatic regulators.
- Do you need a sensor to measure flow? It is not strictly required, but including sensors is advisable to control the system’s condition and make efficiency-driven decisions in industrial processes.
- Is an air lubricator necessary? Most SMC pneumatic actuators are pre-lubricated, so a lubricator is not always required. However, for high-frequency applications or actuators without internal lubrication, using a lubricator is recommended.
If you want to build a custom air treatment unit to match your requirements, try our airline equipment configurator, which allows you to design a solution precisely adapted to your line.
What maintenance does an air treatment (FRL) unit need?
Correct filter maintenance is key, as saturated cartridges commonly cause failures in components of the compressed air network, including actuators, valves, and maintenance units.
SMC recommends changing the filter cartridges every 2 years, or before if the pressure drop goes beyond 0.1 MPa (1 bar), to maintain optimal performance.
Get in touch with our experts to find the air treatment unit that best fits your application.
