Sustainability in manufacturing

Automation solutions may enable faster, more flexible and more cost-efficient production, but they also consume a great amount of energy – whether to generate compressed air in pneumatic systems or to operate electric components. We help you to make your automation as energy-efficient and CO₂-neutral as possible, for example with the energy efficiency modules MSE6 or our Energy Saving Services, which are certified by the German Technical Control Board (TÜV). You can potentially save up to 60% on energy. Why not do something positive for your business and for the environment? We’ll show you here how you can do this.

Sustainability times four

Festo has been promoting the topic of energy efficiency across all sectors for decades: in the company itself, through research projects, in cross-industry committees and with a range of solutions geared towards sustainability.

We support you in four core areas to achieve greater sustainability in manufacturing: our products and solutions have the greatest impact on your energy footprint and on protecting the climate. The sustainability of our portfolio extends from its production and operation, right through to the end of its long service life. We support you with digital tools for the design of energy-efficient systems. Our services help you to identify potential savings in your compressed air system and our offer of basic and further training gives your current and future experts the knowledge they need to work sustainably. Improve your energy efficiency and productivity with us. We are your partner on the journey to CO2-neutral production.

Products for sustainable operation

Service unit combination

Service unit combination MSE6-C2M

Regulating, switching, measuring: complete control of the compressed air supply! The MSE6-C2M monitors the consumption, blocks the compressed air during unproductive times and ensures a soft restart because the pressure never drops below a specific level.

Service unit combination

Service unit combination MSE6-E2M

MSE6-E2M constantly monitors the compressed air consumption, blocks the compressed air after waiting a specific period once production has stopped and reduces the system pressure to 0 bar. It can be integrated directly into PROFIBUS, PROFINET, EtherCAT or Ethernet/IP via fieldbus.

Service unit combination

Service unit combination MSE6-D2M

Automatically save energy in compressed air systems with the MSE6-D2M! The MSE6-D2M monitors consumption, blocks the compressed air during unproductive times and reduces the pressure to 0 bar. For a second compressed air line, you can connect it to the new MSE6-C2M or a CPX terminal.

Flow sensor

Flow sensor SFAM

Keep a constant eye on compressed air consumption with the SFAM. It provides information on flow rate and air consumption and can be used as a stand-alone device or in combination with a service unit from the MS series. Excessive air consumption is often an indicator that savings can be made.

Regulator plate for MPA-S

Regulator plate for MPA-S

Make energy savings of up to 22%: the working pressure for individual cylinders can be regulated directly at the valve terminal with the pressure regulator plate (vertical stacking). Check where you can reduce the pressure level for certain automation tasks.

Motion Terminal

Motion Terminal VTEM

Digitised pneumatics: the Motion Terminal VTEM from Festo uses apps to control consumption in line with the application. And piezo valves reduce energy requirements for pilot control by up to 70%.

Linear drive, metric

Linear drive, metric DGO

Rule out leakage losses: the linear drive features magnetic force transmission without a mechanical connection. This means that the cylinder chamber is hermetically sealed from the outer slide.

Linear drive

Linear drive DGC

Systematically reduce compressed air consumption: the patented sealing band in the rodless drive’s sealing system is virtually leak-free, which is particularly beneficial for long strokes.

Vacuum generator

Vacuum generator OVEM

Reduce energy consumption by up to 60%: the intelligent vacuum generator OVEM ensures a safe stop and prevents constant air consumption with an air-saving circuit. It monitors the vacuum pressure and generates vacuum only when needed.

Save energy with good design

Your applications are most efficient when they are tailored exactly to your individual requirements. By selecting the right technology and optimally sizing components, you will create the framework for long-term energy savings. And by using our numerous engineering tools this process is made even easier.

Pneumatic or electric – what is more efficient?

Sustainability in automation starts right at the design stage of your system. By choosing the right drive technology, you can ensure that the system is as energy-efficient as possible throughout its service life. Criteria such as dynamic response, force, control characteristics, load stiffness and, of course, economic efficiency always play an important role here. An appropriate combination of both technologies is, in many cases, the best solution.

Energy-efficient handling system

Electric – energy-efficient for dynamic motion
Electric automation technology offers energy-efficient solutions for highly dynamic, linear or rotary multi-axis movements in flexible configurations – with excellent accuracy and great force.

Pneumatic – energy-efficient holding, tensioning and clamping
This cost-effective and low-maintenance technology enables energy-efficient movement between two end positions, for example in holding, tensioning, clamping and pressing applications. The simple and robust pneumatics technology can be found in nearly all segments of the automation industry.

Servo-pneumatics – energy-efficient for large loads
If you need to position heavy loads from 15 kg to 300 kg, servo-pneumatics is an energy-efficient and attractively priced solution. Drive packages based on this technology are characterised by fast switching from position control to force control and gentle travel to different positions.

More support for selecting technology is available in the Automation Guide (PDF)

Or you can read our white paper "Pneumatic or electrics" (PDF)

What are your application’s CO2 values and TCO?

CO2 TCO tool from Festo

Before choosing the technology for your system, you should know how high the CO2 consumption will be in the operating phase and what you can expect the total cost of ownership (TCO) to be in the future.

Our CO2 & TCO Guide enables you to compare electric and pneumatic drives from our product portfolio. The tool provides a clear comparison of the energy consumption, CO2 emissions, the procurement costs and the total cost of ownership and so offers you a valuable decision-making support based on the key factors.

Start CO2 & TCO Guide

Find the right product quickly and easily

Engineering on a laptop

Intelligent engineering design focuses on perfectly adjusting the size of components and on selecting the optimal control concept.

Our digital engineering tools make it easier to create an energy-efficient design for your systems. Tailoring the size of the pneumatic drives to fit the requirements can save up to 40% of an application’s air consumption. Evaluation matrices, cost calculators and simulation software help you to make the right decisions from the start and to optimise the systems for your specific applications.

To the engineering tools overview

Sustainability in basic and further training

Energy efficiency and sustainability start in the minds of your employees. Festo Didactic is the world’s leading specialist in technical education. We teach the specialists of today and tomorrow the knowledge and skills they need to identify potential savings in their work and implement them systematically, from the design of your systems through to day-to-day operation.

Top tips for greater energy efficiency

There are many ways to significantly increase energy efficiency and thus also the productivity of your systems, from the comprehensive planning of new systems to simple measures during operation. The following energy-saving tips for pneumatic and electric automation solutions will help you move much closer to the goal of CO2-neutral production.

Choose the right components

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Energy efficiency measures start at the planning stage. Carefully selecting the right drive type for the application is crucial. Single-acting cylinders or a pressure-reduced return stroke can noticeably decrease compressed air consumption. Or use pressure regulating plates and pressure regulators. For long periods of standstill, servo/stepper motors with a holding brake are recommended, for example.

Festo engineering tools help you to select the right product for your application.

Select sizing to suit requirements

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Energy consumption is heavily influenced by the design of the drives. Oversized drives must be avoided at all costs. The smaller the drive, the more energy-efficient it is.

  • Make sure you select the safety factors correctly and keep moving masses low. For pneumatic drives, this can save up to 40% of the air consumption for an application.
    For example: with the standards-based cylinder DSBC reducing the size from 40 to 32 achieves an energy saving of approximately 35%.
  • By designing the drive system as a whole and thus selecting the optimum size, you will avoid an accumulation of safety factors. The Festo engineering tools help you do this. These include practical calculators, simulation software and configuration tools such as the design and simulation tool Electric Motion Sizing, the Solution Finder Simplified Motion Seriesor our Simplified Motion Series.

Save on weight

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It takes energy to move weight. You should therefore keep moving masses low, for example by ensuring everything is correctly sized, by combining components and by choosing lightweight products.

  • If the payload and cycle times of your application allow, you can opt for a technology mix by combining an electric handling system with a lightweight pneumatic Z-axis.
  • Pneumatic grippers are lighter than electric grippers. This saves weight and energy in moving applications.
  • Lightweight products don’t just reduce energy consumption. Because lightweight products need less material, they also have a better CO2 footprint.

Minimise friction

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The lower the friction, the lower the energy losses and the longer the lifespan. It is best to use low-friction components to ensure sustainable operation.

  • Our pneumatic mini slides DGSL or DGST offer highly accurate motion with minimal friction.
  • You should service electric drives and axes regularly to reduce frictional losses.
  • Always check whether a gear unit is really necessary or if you can do without it.

Recover energy

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In many applications, electric drives not only have to accelerate loads, they have to actively decelerate them too. This braking energy can be reused under certain circumstances to save electrical energy, for example with a DC link coupling.

In applications in which the acceleration and deceleration phases of different drives take place simultaneously, you can couple the intermediate circuits of the controller and store the braking energy there. The motor controller CMMP-AS helps you do this.

Switch off energy as often as possible

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In some work cycles, the energy supply can be temporarily stopped – for zero energy consumption and zero leakage.

  • Switch off the air supply whenever possible, for example during machine standstills, at the end of shifts or during breaks. This happens automatically with our energy efficiency module from the MSE6 series.
  • To prevent non-productive idling, it should be possible to switch off the entire system, as well as individual units or components. Make sure you use a safe sequence for shutdown and start-up.

Efficient control and regulation

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In electric automation technology, optimum controller settings with flat acceleration ramps reduce energy consumption and minimise vibrations.

  • You can use our configuration and commissioning software, the Festo Configuration Tool FCT to set good control behaviour with few oscillations and controller interventions for axis systems. A rigidly assembled axis and motor also plays an important role.
  • Digitised pneumatics with the Motion Terminal VTEM offers a wide range of Motion Apps for controlling the connected pneumatic drive components in the most energy-efficient way possible.

Generate vacuum pressure as required

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Constant vacuum pressure is not absolutely necessary for the reliable holding of objects. Continuous air consumption can be avoided by using an air-saving circuit, especially in the case of smooth surfaces and non-porous material. The aim is to use vacuum only when needed.

The vacuum generator OVEM and the vacuum generator VADMI with intelligent vacuum monitoring generate a vacuum only when it is needed and can switch off automatically. The savings amount to roughly 60% of previously required compressed air volumes.

Reduce the pressure level

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There are various ways to reduce the pressure level and therefore also reduce energy costs.

  • An unnecessarily high pressure level across the entire network requires a lot of energy. By reducing the system pressure by 1 bar, you can save up to 10% on the total energy consumed.
  • Some machines require a constant minimum pressure level. If some applications need a higher pressure level at certain points, this can be supplied locally, for example with the pressure booster DPArather than by increasing the pressure in the overall supply network.
  • If an application requires the full force only in one direction of movement or if the drive can generally be operated with a lower pressure, the pressure for the return stroke can easily be reduced by half. This is especially easy to achieve if valve terminals with vertical stacking/regulator plates are used. Compressed air consumption can be reduced by more than 20% by using our regulator plates VMPA1 and VABF.

Reduce pressure loss

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Correct compressed air preparation not only increases the service life of components and systems, it also increases productivity and energy efficiency. This is where care and attention pay off in the long run. Our service unit series MS offers suitable solutions, including in a mix of sizes.

  • Sizing the compressed air preparation system appropriately is important, including with regards to the service unit components. Check that filters are used wisely, because every filter stage reduces the flow rate and increases the pressure drop.
  • Regular maintenance and correctly selected compressed air quality can reduce energy consumption during compressed air preparation by up to 20%. Timely replacement of filter elements in service units prevents unnecessary flow resistance.
  • It‘s advisable to use fittings with minimal flow resistance in the piping system. The lines that feed into the systems and the valves or valve terminals should be large enough to prevent pressure losses.
  • Use multiple distributors instead of connecting T-junctions in series. This reduces the pressure drop.

You can find out more about selecting the optimum service unit combination in our white paper "Compressed air preparation in pneumatics" (PDF)

Reduce tube lengths

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Many tubes between valves and actuators are too long and increase the compressed air consumption through what is known as dead volume. This non-productive air also has a negative impact on the system's cycle times. The dead volume in the tubing frequently accounts for a large percentage of overall consumption, especially in drives or grippers with a small volume.

  • Make sure the tubing lengths are kept as short as possible and are optimally installed. Above all, we recommend positioning valve terminals decentrally.
  • Cut tubing to length with a suitable tool, such as the pipe and tubing cutter ZRS to ensure tight joints and avoid leakages.

Reduce leakages

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Always remember that undiscovered leakages cause unnecessary energy costs around the clock. We know from experience that leakage rates can be reduced by up to 20% in existing systems. It is therefore important to check the compressed air system regularly and check for leakages.

  • We use our Energy Saving Services to detect leakages for you quickly and reliably and put a stop to compressed air losses.
  • Moisture, contamination and oil have a negative effect on seals and wash the initial lubrication out of the components. That’s why we recommend using decentralised compressed air preparation directly at the system.
  • Choose tubing materials that are appropriate for the environment. This will prevent chemical, physical and microbial damage and therefore also leakages.
  • Fittings with modern sealing rings and support functions ensure leakproof, reusable connections.

You can find even more potential energy savings for compressed air systems in our white paper "Reduce energy costs in compressed air systems by up to 60%" (PDF)

Permanently monitor compressed air

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Install a permanent energy monitoring system and monitor your use of compressed air. In principle, every single form of energy should be monitored by sensor technology – in pneumatics primarily with flow sensors.

  • Using flow measurements, you can quickly and easily identify deviations from the ideal state, for example due to leakages or pressure losses. You can then use this knowledge to introduce the right energy-saving measures.
  • Permanent compressed air monitoring instantly brings transparency to compressed air consumption. If the flow value is too high, this can often indicate a saving potential.
  • Monitor the air consumption so that you can take action in the event of deviations. Continuous compressed air monitoring provides continuous reliability.
  • Make use of predictive energy management. By using artificial intelligence, it is possible to predictively calculate how the state of your systems will change over time. We do this with the help of our software Festo Automation Experience (Festo AX).

Would you like to know more? Then you can download our 144-page Tips and tricks for saving energy in pneumatics (PDF) in which we have collated tips per product category.
Simple and advanced application solutions help you to make optimum use of your compressed air components and keep your energy consumption down.

You can rely on the technical experts and efficient technologies from Festo to ensure that your machines and systems consume fewer resources and less energy in future. This will reduce not only CO2 emissions, but also your operating costs – while simultaneously increasing the sustainability of your production processes and your company’s productivity. Our knowledge, experience and products can be found in the manual Energy efficiency@Festo (PDF) .