3 Proven Practices to Extend the Life of Your Pneumatic Equipment

26 June 2025 | IMI Norgren

• Automation & Robotics
• Machinery, Tooling, Production- and Safety Equipment

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Pneumatic systems are critical to industries like manufacturing, material handling, agriculture, and packaging.

1. Control Contamination by Selecting the Right Filter

Contaminants like water, dirt, dust, and oil are common in compressed air systems and can cause damage over time. As air is compressed, these particles become more concentrated, increasing the risk of wear and system failure.

To prevent this, air preparation is essential. Selecting the right filter is just as important as having one in your system. Choosing a filter that’s too fine may increase pressure drop and strain your system. One that’s too large might not filter contaminants effectively.

Here’s a basic guide to filter types:

> General Purpose Filters (5–40 microns): Remove dirt, dust, and moisture

> Coalescing Filters (0.01 micron): Catch oil droplets

> Vapor Removal Filters: Eliminate oil vapor down to 0.003 mg/m³

Match the filter type and micron rating to your application to maintain proper airflow, protect equipment, and minimise unplanned downtime. As contamination builds in the system, production efficiency decreases and maintenance costs increase. Proper filtration is a critical first step in preventing these issues.

2. Stick to a Maintenance Schedule

Filters need to be replaced on a routine basis to stay effective. As filters collect contaminants, their ability to function properly decreases, leading to higher pressure drops and potential equipment issues.

Here are general guidelines for filter replacement:

> General Purpose Filter: Replace every 6 to 12 months

> Coalescing Filter: Replace every 6 months

> Vapor Removal Filter: Replace after 1,000 hours of use

Pressure drop indicators, found on both Excelon® and Excelon® Plus General Purpose and Coalescing filters, signal when replacement is needed. Also, using automatic drains is highly recommended. These prevent contaminants from building up and reentering the system, which helps keep the filtration process effective and reduces manual maintenance tasks.

3. Regulate Pressure

Running pneumatic systems at higher pressure does not mean better performance. In fact, excessive pressure can lead to premature wear and component failure.

Maintaining the right pressure helps save energy, lower costs, and improve system longevity.

Here are some additional suggestions to help regulate pressure effectively:

> Use pressure regulators to maintain consistent pressure throughout the system.

> Install sensors to monitor and control pressure at key points.

> Lock regulator knobs to prevent accidental or unauthorized adjustments.

Air preparation plays a vital role in keeping your pneumatic equipment running efficiently and reliably. By staying ahead of contamination, selecting the right filters, following a maintenance schedule, and regulating pressure, you can extend the life of your system and avoid costly downtime.

These best practices make the difference between reactive repairs and long-term reliability. To learn more tips about optimizing your pneumatic equipment's air preparation system, watch our in-depth webinar: https://register.gotowebinar.com/register/8418561855714181722