Compressed air preparation

Compressed air preparation

Anyone who wants to ensure maximum process reliability and machine availability must include proper compressed air preparation as part of the system right from the planning stage. Because a clean compressed air supply without particles, water or oil helps to avoid malfunctions in pneumatic components, increases the service life of the components and reduces machine failure as well as downtime. Festo offers you systems that ensure compressed air purity in accordance with ISO 85731:20110.

Compressed air preparation – systems from Festo

Our service units are the centrepiece of our solutions for compressed air preparation. They ensure the compressed air quality is right by filtering out compressor oil, condensate and dirt particles from the air. Depending on the application, a service unit consists of a pressure regulator, various filters, a branching module and pressurisation and exhaust valves. At Festo, different combinations are available from stock. In addition, service units can be configured individually in the MS modular system.

Air preparation combination units

The Festo range also includes matching filter regulators, compressed air filters, lubricators and pressure regulators. In addition, we offer on/off valves and soft-start valves, compressed air dryers, compressed air distributors and pressure boosters. Our compressed air preparation is rounded off by condensate drains, pressure indicators and a comprehensive range of accessories.

Service: Compressed air consumption analysis

Optimum compressed air supply, reliable cost planning, safe processes: our qualified service technicians determine the individual compressed air consumption of your machine and provide you with all the facts for greater reliability, efficiency and transparency.

Our service package includes:

  • Specification of the static compressed air consumption of machines when at standstill and when in operation
  • Determination of leakage losses
  • Installation and removal of the measured section with standard parts (fittings, tubing, etc.)
  • Analysis of the measurement results
  • Documentation of the measurement results

The benefits to you:

  • Optimal compressed air supply
  • Reliable processes
  • Reliable cost planning

Festo Energy Saving Services

Why compressed air preparation?

Untreated compressed air contains contamination in the form of particles, water and oil. Water and oil can either be liquid or gaseous and change from one state to another within the compressed air system. None of these three contaminants is present in a compressed air system in their pure form; they form a mixture. The composition of this mixture can vary greatly at different times and in different places in the system. For example, water can collect in branch lines or particles can become deposited in dead spaces over time, and then be suddenly propelled along by a pressure surge.

Each cubic metre of compressed air contains millions of dirt particles, significant quantities of water and oil and even heavy metals such as lead, cadmium and mercury. If these are not filtered out, there can be no guarantee that the system components will continue to work properly in the long term. What's more, these hazardous materials considerably impair product quality. Correct compressed air preparation is therefore vital in order to reduce machine breakdowns and downtime and guarantee process and product reliability.

Poorly prepared compressed air causes malfunctions such as:

  • Fast seal wear
  • Oiled-up valves in the control section
  • Contaminated silencers

Possible effects on the user and machine:

  • Reduced machine availability
  • Higher energy costs due to leakages
  • Higher maintenance costs
  • Shorter component and system service life

How clean should compressed air be?

Compressed air must be so clean that it cannot cause any malfunctions or damage. As each filter also creates a flow resistance, for cost reasons compressed air should only be as clean as necessary. The wide application range of compressed air places many different requirements on compressed air quality. If high quality air is required, several filtration stages are necessary.

How clean the compressed air must be is regulated by ISO 8573. This is the name of a group of international standards for purity requirements for compressed air that specifies the maximum levels of solid particles, water and oil that can be present in the different compressed air classes. This standard has been mandatory for pneumatic automation since 2010. It is therefore essential to observe certain parameters in order to achieve energy-efficient compressed air preparation in compliance with this standard. Festo service unit components and filters ensure trouble-free operation. You can find out which standard your application must comply with in our brochure entitled "Safe processes through perfect compressed air preparation".

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Engineering tool for compressed air quality

Our engineering tool can help you choose the right combination of service unit components for your compressed air preparation. The software tool helps you to correctly configure a service unit. Enter the required compressed air quality on this page, either using your application, an ISO code or via the free filter selection.

To the engineering tool

Service: Compressed air quality analysis

Clean compressed air – reliable processes and an increased service life for all pneumatic components. Our qualified service technicians analyse the quality of your compressed air directly at the extraction point.

Our service package includes:

  • Inspection of decentralised compressed air preparation at its extraction point
  • Measurement of the residual oil content (up to ISO 8573-1:2010 class 2)
  • Measurement of the pressure dew point (up to ISO 8573-1:2010 class 2)
  • Analysis of the measurement results and recommendations for improvement
  • Documentation of the measurement results
  • Additional measurements on request

The benefits to you:

  • Increase in the service life of pneumatic components
  • Identification of weak points
  • Increase in process reliability

Festo Energy Saving Services