Reducing Energy Costs is Key to Sustainable Manufacturing
If you think high energy costs in manufacturing are inevitable, we have a solution that shows how you can achieve significant savings without expensive investments in new technology. Our experience shows that even without changes to machines, you can achieve savings of up to 28% in energy consumption simply by optimizing your pressure systems.
By Petr Čečák, Customised Services, SMC Czech Republic
JULY 2025
Why Is High Pressure a Problem?
In many industrial plants, the working pressure in pneumatic systems is historically set, often unnecessarily high. While 7.5 bars is common, this level of pressure leads to excessive energy consumption. According to SMC data, reducing pressure by 1 bar can save up to 8% of energy. High pressure means unnecessarily high air compression costs, which negatively impact the overall energy balance. Our solution? Reduce the pressure in the system to an optimal level that is energy-efficient, without making changes to the machines themselves.
Step-by-Step Pressure Optimization: Safe and Effective Cost Reduction
Our approach to pressure optimization is systematic and safe. We gradually reduced the pressure, step by step, by 0.1 bar. This controlled process took about six months, during which we carefully monitored the stability of the entire system and ensured there were no negative impacts on productivity. Part of the solution also involved deploying four pressure multipliers at critical points where higher pressure was required for specific applications (e.g., cylinders, vacuum systems, blowers). This way, we could lower the overall pressure in the system without compromising performance.
Results: Savings That Speak for Themselves
After implementing the optimization, we achieved the following results:
- Working Pressure: The working pressure in the system was 7.5 bar before optimization. After reducing it to 6.0 bar, we lowered the pressure by 1.5 bar.
- Energy Consumption: The energy consumption for producing 1 m³ of compressed air was 0.121 kWh before optimization. After reducing the pressure, it dropped to 0.087 kWh, representing a 28% saving.
- Machine Construction Intervention: Unlike other methods that often require modifications to machines or equipment, our solution did not require any changes to the machine construction.
- Impact on Productivity: Throughout the entire process, there was no reduction in productivity or machine performance.
These changes not only led to significant savings but also extended the lifetime of components, reduced losses caused by leaks, and improved overall operational stability.
Why Does It Work? Optimization Is Effective and Environmentally Friendly
Compressed air is one of the most energy-intensive media. In Europe, around 87 TWh of electrical energy is consumed annually to produce compressed air, which corresponds to emissions of 84,000 kilotons of CO₂. Despite this, pressure in many systems is unnecessarily set too high, increasing energy consumption. By reducing the pressure in systems, we can significantly reduce energy consumption and CO₂ emissions. In addition to saving costs, this also contributes to environmental protection.
Advantages of Reducing Pressure in Pneumatic Systems
Energy savings: By reducing pressure by 1 bar, you can save up to 8% of energy.
Lower operating costs: Reduced energy consumption immediately reflects in reduced operational costs.
Longer equipment lifetime: Optimized pressure results in less wear on components, extending their lifespan.
Lower CO₂ emissions: Reducing energy consumption also reduces greenhouse gas emissions.
Higher stability and safety: Lower pressure means fewer issues with leaks and more stable operation.
How to Start: Recommended Approach for Successful Pressure Optimization
Optimising individual machines after understanding demands
If you want to start optimizing pressure, we recommend the following approach:
- Map consumption: Identify current pressure, flow, and intake profiles.
- Gradually reduce pressure: Reduce pressure in small steps (e.g., by 0.1 bar) to ensure stability.
- Install supporting elements: Use pressure multipliers and air tanks for specific applications.
- Verify stability: Monitor performance and quality to ensure system stability and efficiency.
- Establish new standards: Set new standards for operating at lower pressure, including selecting the right components.
SMC offers complete support in every phase of this process, from measurement and design to implementation and training.
Common Concerns and How to Address Them
“Our machines are used to higher pressure.”
Most modern machines operate efficiently even at lower pressure, such as 4 bars.
“We need higher pressure for some applications.”
SMC VBA series pressure boosters
Pressure multipliers allow localized increases in pressure where needed, without affecting the entire system.
“This will be difficult and expensive.”
Reducing pressure is often less costly than investing in new machines and can be done without modifications to machine construction.
Accept the Challenge, Switch to 4 Bar
Reducing the working pressure from 7.5 to 6 bar showed us that you can save up to 28% in energy to produce compressed air without compromising technological processes.
If you want to find out how to lower your costs and improve energy efficiency, contact us. Our experts will help you optimize your pressure system and achieve real savings.
SMC – Ready for 4 bars. Ready for a sustainable future. Accept the challenge
