Step-by-step digitalisation of your compressed air system

Interested in digitalisation, but not sure where to begin?

You're not alone. Many plant managers today understand the growing importance of digital transformation but feel uncertain about how to take the first step, especially when it comes to something as essential (and often overlooked) as compressed air systems. With concerns around costs, system compatibility, and operational complexity, it’s easy to feel stuck.

At SMC, we understand these challenges. That’s why we focus on realistic, regulation-ready compressed air digitalisation solutions designed to evolve with your factory. Whether you're operating with manual gauges or already exploring IO-Link, wireless systems, or centralised data acquisition, our goal is to help you take the next logical step toward efficiency, transparency, and sustainability.

Digitalising your compressed air system isn’t just about adopting new technologies, it’s about gaining control, reducing energy costs, and preparing for a future shaped by Industry 4.0 and environmental regulation.

With tailored guidance and proven solutions, SMC is here to support you at every stage of your digitalisation journey.

What is compressed air digitalisation?

In today’s smart factories, digitalisation is a strategic enabler – not just a buzzword. It involves the real-time collection and integration of data through technologies like smart sensors, industrial IoT, data analytics, and networked control systems to deliver greater visibility, control, and operational efficiency across production processes.

When applied to compressed air systems

• Reduce waste
• Improve air system performance
• Extend equipment life
• Minimise downtime

Instead of relying on manual inspections and guesswork, manufacturers can access real-time performance data, automate system control, and make informed, data-driven decisions

At SMC, we define compressed air digitalisation through three key stages:

1. Monitoring – Real-time visibility for your compressed air system

Gain visibility into your compressed air system. Install sensors to track pressure, flow rate, temperature, and humidity, among others. View live dashboards and receive alerts when anomalies occur, and start identifying improvement areas immediatly.

Key benefits:

• Real-time condition tracking
• Foundational data for process improvement

2. Control – Automated air system management and response

Move from observation to action. Automate pressure settings, enable remote configuration, and create feedback loops that respond to performance deviations

Key benefits:

• Reduce manual intervention
• Maintain stable process conditions
• Enable machine-level intelligence

Whether you're just starting your digitalisation journey or already have connected technologies in place, SMC supports your progress with step-by-step upgrades and expert guidance tailored to your factory's current level of digital maturity.

AÑADIR TEXTO AQUI

Discover SMC’s digital architecture: A practical, scalable approach to compressed air digitalisation

Digitalising your compressed air system doesn’t have to be complex or disruptive. At SMC, we offer a modular and scalable Digital Architecture designed to adapt to your specific needs, no matter where you are in your digitalisation journey.

• Flexible Implementation

There’s no one-size-fits-all approach to digitalisation. That’s why at SMC, we design our products to be versatile, modular, and highly compatible – enabling you to easily find a solution tailored to your specific application, regardless of its size or complexity.

• Seamless Integration

Easily connect your compressed air system to the industrial network using IO-Link, wireless communication, or fieldbus protocols. SMC solutions integrate smoothly with existing PLCs, SCADA systems, and MES platforms, ensuring minimal disruption and maximum compatibility.

• Data availability

With access to real-time compressed air data, you can transform raw information into actionable insights through dashboards, alerts, and historical data logs. Manage your entire system from a centralised interface, and scale visibility across multiple factory locations for consistent performance tracking.

• Open and Future-Ready

Our Digital Architecture is based on open, industry-standard protocols such as OPC UA, offering seamless interoperability, long-term scalability, and vendor-neutral integration – making your compressed air system ready for tomorrow’s technologies.

SMC’s Digital Architecture gives you the flexibility to start small and grow smart, unlocking long-term benefits such as energy savings, predictive maintenance, and improved process stability.

Whether you're upgrading a single line or building a full smart factory, we’ll guide you with tailored solutions and proven technology.

Where are you on your digitalisation journey?

Not every factory starts from the same point. That’s why SMC offers a structured, scalable approach to help manufacturers assess their current level of digitalisation and plan their next steps effectively.

Our framework is built around three progressive levels of digital maturity. Identifying where your plant stands can help prioritise investment, streamline deployment, and maximise ROI.

Level 1 – Basic Digitalisation

Operations rely on manual checks and standalone analogue instruments. There is limited visibility and no access to real-time data.

• Manual pressure and flow readings
• No alerts or remote access
• Maintenance is reactive

Recommended next steps: Introduce digital pressure sensors, flow switches, and basic condition monitoring.

Level 2 – Moderate Digitalisation

Some digital components and IO-Link devices are in use. Data is captured locally but not fully networked or centralised.

• Partial digital monitoring
• Local feedback loops
• Energy usage awareness begins

Recommended next steps: Connect devices via IO-Link or wireless systems, enable remote configuration, and start benchmarking performance.

Level 3 – Advanced Digitalisation

A fully connected architecture enables real-time data exchange, predictive analytics, and cross-factory optimisation.

• Centralised dashboards and data acquisition
• Predictive maintenance in place
• Integration with MES/SCADA platforms

Recommended next steps: Scale insights across sites, integrate digital twins, and use AI-based analytics to fine-tune operations.

With technologies like IO-Link, wireless communication protocols, and our Air Management System (AMS), SMC enables manufacturers to progress through these stages at their own pace — with minimal disruption and clear ROI.

Digitalisation Starts with a Simple Conversation

At SMC, we offer personalised evaluations to help you identify the next best step based on your current setup. Simple, practical, and without overcomplicating things.