SMC Energy Saving: Saving Compressed Air Systematically

Compressed air is one of the most expensive forms of energy in manufacturing: pneumatics account for around 20% of a plant's electricity consumption, and according to SMC's experience 30–50% of the compressed air produced is lost through leaks and inefficient use. As an SMC partner, we show you where compressed air can be saved and which SMC products fit.

4BAR Factory: The simplest lever

The 4BAR Factory is an SMC concept: the supply pressure in the factory is lowered from the usual 6 bar to 4 bar. SMC regards 4 bar as the optimum for generation, distribution and operation of machines. More from the manufacturer: SMC 4BAR Factory ↗.

  • Less air consumption: At 4 instead of 6 bar, air consumption falls by around 29% (roughly one third).
  • Lower electricity costs: According to SMC, each bar less pressure saves 6–8% of the electricity costs of air generation.
  • No investment needed: Lowering the operating pressure costs nothing at first.
  • Less wear and noise: Components are under less stress and leaks lose impact.

Many plants are oversized and run reliably at lower pressure as well. SMC recommends lowering the pressure step by step in tenths of a bar and observing the plant over a defined period. If force is no longer sufficient at individual points, a pressure booster (VBA) can be used locally instead of keeping the whole network at high pressure.

Where is the saving potential?

1. Lower the pressure

Many plants run at 6–7 bar. According to SMC, every bar less reduces specific energy demand by 6–8% on average; at 5 bar savings of up to 15% are possible, at 4 bar up to 29%. Cylinder return strokes often need only 2 bar or less.

  • JSB – angle seat valve for 3 bar supply pressure
  • CQE – high-force cylinder that allows lower operating pressure
  • KNH – efficient air nozzle that keeps blow performance at lower pressure
  • ZL – multi-stage ejector, from 3.5 bar supply pressure
  • VBA – pressure booster regulator: higher pressure locally without raising the main line

2. Find and eliminate leaks

Depending on the plant, 20–50% of compressed air is lost through leaks. An ongoing programme of ultrasonic leak detection, prioritisation and repair is effective. More on our page Compressed air leak measurement.

3. Optimise blowing and vacuum

According to SMC, blowing accounts for around 42% of global compressed air consumption and vacuum generation for about 9%. This is where the most can be saved:

  • IBG / IBV – Impact Blow Gun and Impact Blow Valve: SMC states up to 87% less air consumption compared with conventional blow guns
  • VMG – blow gun with nozzle options, optionally with pulse blow unit
  • ZK2 – vacuum unit with two-stage ejector and energy-saving digital vacuum switch: around 90% less air consumption
  • ZL – multi-stage vacuum generator
  • ZHV – vacuum flow multiplier: blowing air ×4, suction air ×3

4. Reduce consumption at the machine

  • ISA3 – digital gap checker for workpiece detection: up to 60% less air consumption
  • CVQ – compact cylinder with integrated valve: approx. 50% less air consumption
  • CDQ2B-X3150 – air-saving compact cylinder that reuses exhaust air: up to 46% less air consumption
  • ASR / ASQ – air-saving speed controllers: up to 25% less air consumption
  • AMS20-60 – Air Management System for savings at machine level
  • PF3A – digital flow switch with IO-Link for consumption monitoring

If lower pressure is combined with these measures, SMC cites typical total savings of around 75%. The figures are manufacturer data and depend on the individual case.

Sizing cylinders correctly

Compressed air can also be saved with standard cylinders without changing the series. You will find the complete SMC range in our overview Cylinders and pneumatic actuators. These measures help most:

  • Do not oversize the bore: Air consumption grows with piston area. A cylinder with high force output such as the CQE often allows a smaller bore.
  • Adapt the pressure to the cylinder: The return stroke often needs only 2 bar or less; a separate pressure regulator for each stroke direction saves air.
  • Limit the stroke to what is needed: Every unnecessary millimetre of stroke has to be filled with compressed air.
  • Valve close to the cylinder: Short lines reduce dead volume. On the CVQ the valve is mounted directly on the cylinder.
  • Low-pressure applications: According to the SMC datasheet, the low-friction MQQ operates from 0.005 MPa (0.05 bar) operating pressure (horizontal, bores 10–40 mm) and consumes correspondingly little air.

Calculator: What does your compressed air cost?

Set your compressed air consumption and costs with the sliders or type the values in directly. The defaults are guide values for a medium-sized industrial plant.

Air consumption per year
Electricity consumption per year
Electricity cost per year
Electricity cost per m³ of compressed air
Of which lost through leaks
Saving from pressure reduction (6–8% per bar)
Guide values: In practical analyses the energy demand of air generation is mostly around 0.10–0.15 kWh per m³ (approx. 6.5 kW per m³/min at the compressor, usually higher including drying, treatment and distribution). The electricity price of 0.20 €/kWh is roughly what medium-sized industrial companies in Austria pay (about 20 ct/kWh incl. levies in 2025 according to Österreichs Energie); please replace it with your own tariff. The saving per bar is based on SMC's figure of 6–8%. Electricity costs only, no maintenance or investment. Non-binding example calculation.

Practical examples

The following examples come from SMC application cases. The figures are manufacturer data; savings and payback depend on operating hours and energy price.

  • Washing machine, machining (IBV): Impact blow valves instead of conventional blow nozzles clean the parts faster and with much less air. Savings of about €18,100 per year for an investment of about €2,100, payback in around 1.4 months.
  • Bottle drying before labelling (KNH): Two energy-saving nozzles reduce consumption from 562 to 238 l/min. At 5,000 operating hours and €0.01/m³ this is about €970 saved per year for an investment of €70, payback in under one month.
  • Blow gun with nozzle (VMG + KNH): Instead of 604 l/min at about 6 bar the combination uses about 128 l/min, a reduction of around 78%.
  • Manual blowing (IBG): With the impact blow gun 3–4 bar is enough instead of 7 bar; savings of about €410 per year, payback in just under 6 months.
  • Tool cooling at an automotive supplier (AXTS): The pulse blow valve reduces consumption from 697 to 302 l/min for the same cooling time, about 56% less. Payback about 11 months.
  • Cleaning a workbench (PU): Pulse blow unit with nozzle instead of a standard blow gun: 110 instead of 385 l/min, savings of about €640 per year, payback in around 5 months.
  • Beverage industry: With the ZH20B-X185 air booster, air consumption fell by more than 50% at a pressure below 5 bar; payback was under 450 days.
  • Snack industry: With VMG series blow guns, savings of more than €7,000 per year were achieved, with payback after 247 days.

How to proceed

  1. Visualise the air: record pressure and flow of existing equipment.
  2. Optimise line pressure: find the lowest pressure at which production runs stably.
  3. Adjust plant pressure: lower the supply pressure at the compressor.
  4. Replace consumers selectively: blow nozzles, vacuum and cylinders with the biggest losses first.

SMC supports you with Energy Assessments: experts analyse machines and the compressed air network, search for leaks by ultrasound, check air quality, pressure drops and pipe sizing, and prepare a savings report.

Legislation and funding

Energy efficiency is not only economically sensible: larger companies are subject to the Austrian Energy Efficiency Act (EEffG) and, at EU level, the Energy Efficiency Directive. In addition, measures to reduce energy consumption are subsidised in many countries; according to SMC, grants of up to 30–40% of the investment costs are possible in Austria, Germany and the EU. Contacts include aws and Kommunalkredit Public Consulting (KPC) in Austria and BAFA (module 4) in Germany. Funding conditions change, so please check them for your individual case.

Products for saving compressed air

You will find all the products mentioned in our collection SMC Energy Saving:

Suitable product groups

Sources: SMC expert article on energy efficiency ↗, SMC Energy Assessments ↗, SMC 4BAR Factory ↗, SMC Distribution Days 2026.

Would you like to know where your plant loses compressed air? Get in touch – we will advise you on selecting suitable SMC products and on an energy assessment.