Optimizing energy use and minimizing downtime are more than sustainability goals — they’re business imperatives. That’s where smart Air Management Systems (AMS) come in. These innovative systems are helping manufacturers reduce compressed air waste, extend component life, and make better, data-driven maintenance decisions.

Why Pneumatics Need Monitoring

Pneumatic systems are essential across industries like packaging, food and beverage, and pharma. While they offer reliability and simplicity, they can be energy-intensive — especially when air leaks go undetected or machines stay pressurized during idle time.

Monitoring air flow, pressure, and temperature can reveal inefficiencies and enable predictive maintenance. However, until recently, implementing such monitoring required costly downtime and specialized equipment.

Enter the Air Management System (AMS)

SMC’s AMS is a smart, compact unit that automates air pressure control based on machine state. It can:

• Reduce pressure when machines are idle (standby mode)

• Cut off air supply when machines are stopped (isolation mode)

• Ramp pressure up when production resumes

It also collects high-resolution data via OPC UA and IO-Link — without needing an edge device — and integrates seamlessly with SCADA systems for advanced analytics and condition-based maintenance (CBM).

Case Study: Bottling Line Sees 26% Energy Reduction

A real-world test on a 10-machine bottle filling line showed compelling results:

• AMS units reduced idle air pressure by 63%

• The plant saw a 26% drop in annual energy use

• Compressed air costs dropped significantly with no impact on production

Machines switched from idle (full pressure) to standby or isolation, slashing air waste from leaks and non-essential operations.

More Than Savings — It's Smart Maintenance

The AMS not only saves energy — it enables predictive maintenance. By continuously monitoring pressure and flow, it can alert users to developing issues like leaks or component wear before a failure occurs.

These insights can:

• Minimize unplanned downtime

• Optimize part ordering and maintenance schedules

• Provide benchmarking data across multiple facilities

Final Thoughts

Smart air monitoring isn’t just a sustainability win — it’s a competitive advantage. Whether you’re trying to hit ESG goals, reduce utility spend, or improve production uptime, integrating an Air Management System into your pneumatic machines is a strategic move.

Ready to optimize your compressed air usage? Explore how SMC’s AMS can help your facility cut costs, conserve energy, and stay ahead in the era of Industry 4.0.