Preparing a compressed air installation for future expansion begins with calculating your current and expected air demand, followed by installing oversized piping and electrical infrastructure. Choose modular compressor systems with parallel configuration and reserve sufficient space for additional compressors. Good planning prevents costly modifications later.
Why Forward Thinking for Your Compressed Air Installation Is Important
Strategic planning for compressed air installations prevents expensive modifications later and optimizes your investments. The difference between planning ahead and expanding afterward can save thousands of euros.
When you must expand afterward, problems often arise with undersized pipes, insufficient electrical capacity, and space limitations. These modifications require production downtime and additional work on existing installations.
Planning ahead means that you account for growth from the beginning. You then directly install piping with sufficient capacity and reserve space for additional compressors. This not only saves costs but also ensures a more stable compressed air supply during expansions.
Modern compressor control systems enable modular expansion where new compressors integrate seamlessly with existing installations. This increases the reliability of your complete system.
How Do I Determine the Right Capacity for Future Growth?
Begin by measuring your current air consumption during various production periods. Add 20-30% to this for future growth and use a safety factor of 10-15% for unforeseen peaks.
Factors that influence your capacity determination are production growth, new machines, seasonal fluctuations, and process changes. Create an overview of planned investments in new equipment that consumes compressed air.
For a reliable calculation, measure consumption at different times:
- Normal production hours
- Peak moments during the day
- Machine startup phases
- Different seasons if relevant
Compressor sizing also accounts for pressure drop in the piping network. Longer pipes and more bends require extra capacity to maintain the desired working pressure.
What Infrastructure Should I Install Now?
Install piping directly with a diameter that is 25-50% larger than your current need. This prevents costly replacements during expansion and improves pressure stability in your network.
For the electrical connection, reserve sufficient power for future compressors. An electrician can calculate what cable thickness and fuses you need for the planned total capacity.
Important infrastructural preparations:
- Main lines with oversized diameter
- Main electrical cable to compressor room
- Solid foundation for additional compressors
- Sufficient ventilation for heat removal
- Space for air dryers and filters
Modular construction of your compressed air network expansion makes later modifications easier. Use standard couplings and shut-off valves at strategic points for future branches.
What Is the Best Configuration for Expandable Compressor Systems?
Choose a parallel configuration where each compressor can be operated and maintained separately. This offers maximum flexibility for future expansions and increases the reliability of your system.
A master compressor system coordinates the operation of all compressors and ensures optimal energy consumption. Modern control systems can control compressors at different locations via a central point.
Optimal configuration for expandable systems:
- Each compressor has its own shut-off valve
- Common main line with sufficient capacity
- Central air treatment system (dryers and filters)
- Redundancy through multiple smaller compressors
Advanced control systems communicate via digital networks and can automatically adjust the air compressor capacity to demand. This saves energy and extends the lifespan of your equipment.
How Do I Prevent Costly Mistakes When Expanding?
Common planning mistakes are underestimating future consumption, undersized pipes, and insufficient electrical capacity. Professional advice helps avoid these pitfalls.
Time your expansions well by regularly evaluating your compressed air system. Do not wait until you get capacity problems, but expand when you use 70-80% of your current capacity.
Important considerations during expansion:
- Check if your current piping network can handle the additional capacity
- Ensure sufficient electrical power
- Plan maintenance stops for connection work
- Test the expanded system thoroughly before commissioning
Regular evaluation of your industrial compressed air system prevents unnecessary costs. Monitor energy consumption and pressure stability to detect signals for expansion in time.
Smart Planning Saves Time and Money During Expansion
Future-proof compressed air installations are characterized by oversized infrastructure, modular construction, and intelligent control systems. These investments pay back through lower expansion costs and improved efficiency.
Modular systems offer the greatest advantages during expansion because new components can be easily added without major modifications to the existing system. This minimizes production downtime and installation costs.
Professional advice becomes important when you plan complex expansions, need to connect multiple locations, or have specific pressure and quality requirements. A specialist can calculate which configuration is most cost-effective for your situation.
At Presscon, we help you with the design of expandable compressed air installations that grow with your business. Our modular systems and advanced control systems ensure optimal efficiency and reliability, now and in the future.