{"id":8413,"date":"2026-02-10T16:04:43","date_gmt":"2026-02-10T15:04:43","guid":{"rendered":"https:\/\/www.technologybsa.com\/the-4-bar-factory-reduce-operating-costs-and-co%e2%82%82-footprint-with-smc-solutions\/"},"modified":"2026-03-03T16:42:29","modified_gmt":"2026-03-03T15:42:29","slug":"the-4-bar-factory-reduce-operating-costs-and-co%e2%82%82-footprint-with-smc-solutions","status":"publish","type":"post","link":"https:\/\/www.technologybsa.com\/en\/the-4-bar-factory-reduce-operating-costs-and-co%e2%82%82-footprint-with-smc-solutions\/","title":{"rendered":"The 4-Bar Factory: reduce operating costs and CO\u2082 footprint with SMC solutions"},"content":{"rendered":"<section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_2-1 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h2 data-start=\"0\" data-end=\"199\">SMC\u2019s 4-Bar Factory can transform industrial plants by reducing energy consumption by up to 20%.<\/h2>\n<p>&nbsp;<\/p>\n<h3 data-start=\"0\" data-end=\"199\">Energy efficiency is no longer an option\u2014it is a strategic lever for industrial competitiveness.<\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"201\" data-end=\"304\">In today\u2019s industrial landscape, the transition toward sustainable production models is a top priority.<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"306\" data-end=\"445\">With the European Union outlining a clear roadmap toward carbon neutrality by 2050, companies are required to drastically reduce emissions.<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"447\" data-end=\"604\" data-is-last-node=\"\" data-is-only-node=\"\">However, sustainability must go hand in hand with economic competitiveness. This is where the revolutionary concept of the <strong data-start=\"570\" data-end=\"587\">4-Bar Factory<\/strong> comes into play.<\/p>\n<\/div><\/div><\/div><\/div><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"w-image align_center\"><div class=\"w-image-h\"><img decoding=\"async\" width=\"200\" height=\"90\" src=\"https:\/\/www.technologybsa.com\/wp-content\/uploads\/2023\/09\/BSA-marchi-smc.svg\" class=\"attachment-full size-full\" alt=\"\" loading=\"lazy\" \/><\/div><\/div><div class=\"w-separator size_small\"><\/div><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h4>Listen to the podcast dedicated to the 4-Bar Factory<\/h4>\n<\/div><\/div><div class=\"w-video align_none with_overlay has_iframe\" style=\"background-image:url(https:\/\/www.technologybsa.com\/wp-content\/uploads\/2026\/02\/cover-podcast-4-bar.jpg);\" onclick=\"return {&quot;player_id&quot;:&quot;youtube-be88&quot;,&quot;player_api&quot;:&quot;\\\/\\\/www.youtube.com\\\/player_api&quot;,&quot;player_html&quot;:&quot;&lt;div id=\\&quot;youtube-be88\\&quot;&gt;&lt;\\\/div&gt;&lt;script&gt;\\r\\n\\t\\t\\twindow.USYTPlayers = ( window.USYTPlayers || { initYTFunctions: [], optionsYT: [], USYTInited: false } );\\r\\n\\t\\t\\twindow.USYTPlayers.optionsYT.push( {\\r\\n\\t\\t\\t\\tplayerID: \\&quot;youtube-be88\\&quot;,\\r\\n\\t\\t\\t\\tvideoID: \\&quot;khcN6rKBgTE\\&quot;,\\r\\n\\t\\t\\t\\tplayerVars: {\\&quot;autoplay\\&quot;:1,\\&quot;controls\\&quot;:1,\\&quot;origin\\&quot;:\\&quot;https:\\\\\\\/\\\\\\\/www.technologybsa.com\\\\\\\/en\\\\\\\/\\&quot;,\\&quot;loop\\&quot;:0,\\&quot;mute\\&quot;:0,\\&quot;playlist\\&quot;:\\&quot;khcN6rKBgTE\\&quot;}\\r\\n\\t\\t\\t} );\\r\\n\\t\\t\\tif ( window.USYTPlayers.USYTInited === false ) {\\r\\n\\t\\t\\t\\t\\\/\\\/ Trying to override other possible WP YT API calls if our element is used\\r\\n\\t\\t\\t\\twindow.USYTPlayers.USYTInited = true;\\r\\n\\r\\n\\t\\t\\t\\twindow.onYouTubePlayerAPIReady = function() {\\r\\n\\t\\t\\t\\t\\tfor ( var i in window.USYTPlayers.optionsYT ) {\\r\\n\\t\\t\\t\\t\\t\\tvar _playerParams = window.USYTPlayers.optionsYT[ i ];\\r\\n\\t\\t\\t\\t\\t\\t$us.YTPlayers[ _playerParams.playerID ] = new YT.Player( _playerParams.playerID, {\\r\\n\\t\\t\\t\\t\\t\\t\\tvideoId: _playerParams.videoID,\\r\\n\\t\\t\\t\\t\\t\\t\\tplayerVars: _playerParams.playerVars\\r\\n\\t\\t\\t\\t\\t\\t} );\\r\\n\\t\\t\\t\\t\\t}\\r\\n\\t\\t\\t\\t}\\r\\n\\t\\t\\t}\\r\\n\\t\\t\\tif ( !!window.YT ) {\\r\\n\\t\\t\\t\\t$us.YTPlayers[\\&quot;youtube-be88\\&quot;] = new YT.Player( \\&quot;youtube-be88\\&quot;, {\\r\\n\\t\\t\\t\\t\\tvideoId: \\&quot;khcN6rKBgTE\\&quot;,\\r\\n\\t\\t\\t\\t\\tplayerVars: {\\&quot;autoplay\\&quot;:1,\\&quot;controls\\&quot;:1,\\&quot;origin\\&quot;:\\&quot;https:\\\\\\\/\\\\\\\/www.technologybsa.com\\\\\\\/en\\\\\\\/\\&quot;,\\&quot;loop\\&quot;:0,\\&quot;mute\\&quot;:0,\\&quot;playlist\\&quot;:\\&quot;khcN6rKBgTE\\&quot;}\\r\\n\\t\\t\\t\\t} );\\r\\n\\t\\t\\t}\\r\\n\\t\\t&lt;\\\/script&gt;&quot;}\"><button class=\"w-video-play\" type=\"button\" aria-label=\"Play\"><span class=\"w-video-play-icon\" style=\"font-size:1.5rem;background:rgba(0,0,0,0.5);color:#fff\"><\/span><\/button><div class=\"w-video-h\"><\/div><\/div><\/div><\/div><\/div><\/div><\/section><section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_2 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"52\"><strong data-start=\"0\" data-end=\"52\">Compressed air: a valuable (and costly) resource<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"54\" data-end=\"321\">Often referred to as the industry\u2019s \u201cfourth utility,\u201d compressed air represents a major cost factor. In Europe, it is estimated that around <strong data-start=\"194\" data-end=\"204\">87 TWh<\/strong> of industrial electricity are used to generate compressed air, resulting in <strong data-start=\"281\" data-end=\"320\">84,000 kt of CO\u2082 emissions per year<\/strong>.<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"323\" data-end=\"654\" data-is-last-node=\"\" data-is-only-node=\"\">Traditionally, plants operate at pressures of <strong data-start=\"369\" data-end=\"383\">6 or 7 bar<\/strong>, often based on legacy settings or to compensate for leaks and demand peaks. However, maintaining such high pressure entails significant energy waste. The rule is simple: <strong>for every 1 bar reduction in supply pressure, average energy consumption decreases by 6\u20138%.<\/strong><\/p>\n<\/div><\/div><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"22\"><strong data-start=\"0\" data-end=\"22\">Why move to 4 bar?<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"24\" data-end=\"169\">SMC\u2019s proposal\u2014our reference partner for Technology BSA, is bold yet practical: lowering the plant\u2019s standard operating pressure to <strong data-start=\"159\" data-end=\"168\">4 bar<\/strong>.<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"171\" data-end=\"313\" data-is-last-node=\"\" data-is-only-node=\"\">Reducing pressure from 7 to 4 bar is not a simple adjustment, but a strategic shift that can deliver overall energy savings of<strong data-start=\"276\" data-end=\"312\"> 20\u201325%<\/strong>.<\/p>\n<\/div><\/div><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"29\"><strong data-start=\"0\" data-end=\"29\">The benefits are multiple<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<ul>\n<li><strong data-start=\"33\" data-end=\"61\">Reduced operating costs:<\/strong> less work for compressors means lower energy bills.<\/li>\n<li><strong data-start=\"118\" data-end=\"135\">Lower losses:<\/strong> reduced pressure decreases the volume of air lost through system leaks.<\/li>\n<li><strong data-start=\"212\" data-end=\"236\">Reduced maintenance:<\/strong> pneumatic components operating at lower pressure experience less stress, extending their service life.<\/li>\n<li><strong data-start=\"344\" data-end=\"363\">Sustainability:<\/strong> a direct reduction in CO\u2082 footprint, aligned with ESG objectives.<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"w-video align_none has_iframe\"><div class=\"w-video-h\"><iframe title=\"Youtube video player\" src=\"\/\/www.youtube.com\/embed\/CdFMMnKx7qg?autoplay=0&controls=1&origin=https:\/\/www.technologybsa.com\/en\/&loop=0&mute=0\" allowfullscreen=\"1\" loading=\"lazy\"><\/iframe><\/div><\/div><div class=\"w-separator size_medium\"><\/div><div class=\"w-image align_none\"><a target=\"_blank\" title=\"View the PDF\" href=\"https:\/\/www.technologybsa.com\/wp-content\/uploads\/2026\/02\/fabbrica-4-bar.pdf\" aria-label=\"infografica-aria-compressa\" class=\"w-image-h\"><img decoding=\"async\" width=\"400\" height=\"717\" src=\"https:\/\/www.technologybsa.com\/wp-content\/uploads\/2026\/02\/infografica-aria-compressa-e1770742203780.png\" class=\"attachment-full size-full\" alt=\"Fabbrica 4 bar\" loading=\"lazy\" \/><\/a><\/div><div class=\"w-separator size_medium\"><\/div><div class=\"w-btn-wrapper align_none\"><a class=\"w-btn us-btn-style_1\" target=\"_blank\" href=\"https:\/\/www.technologybsa.com\/wp-content\/uploads\/2026\/02\/fabbrica-4-bar.pdf\"><span class=\"w-btn-label\">Download the PDF<\/span><\/a><\/div><\/div><\/div><\/div><\/div><\/section><section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_1 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"51\"><strong data-start=\"0\" data-end=\"51\">How to implement the change: a gradual approach<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"53\" data-end=\"158\">We know resistance to change is strong\u2014\u201cWe\u2019ve always done it this way,\u201d or \u201cThe machines will slow down.\u201d<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"160\" data-end=\"270\">SMC and Technology BSA propose a structured, methodical approach to ensure productivity remains unchanged.<\/p>\n<p>&nbsp;<\/p>\n<h3 data-start=\"272\" data-end=\"353\">The transition to a <strong data-start=\"292\" data-end=\"309\">4-Bar Factory<\/strong> takes place through clearly defined phases.<\/h3>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/section><section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_3 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"30\"><strong data-start=\"0\" data-end=\"30\">1. Analysis and Monitoring<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"32\" data-end=\"145\" data-is-last-node=\"\" data-is-only-node=\"\">Before lowering the pressure, measurement is essential. Demand peaks and inefficiencies must be identified first.<\/p>\n<\/div><\/div><\/div><\/div><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"25\"><strong data-start=\"0\" data-end=\"25\">2. Local optimization<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"27\" data-end=\"242\" data-is-last-node=\"\" data-is-only-node=\"\">Pressure drops are often caused by sudden demand peaks. By installing local reservoirs or regulators close to the point of use, supply can be stabilized without maintaining high pressure throughout the entire plant.<\/p>\n<\/div><\/div><\/div><\/div><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3 data-start=\"0\" data-end=\"41\"><strong data-start=\"0\" data-end=\"41\">The right pressure in the right place<\/strong><\/h3>\n<p>&nbsp;<\/p>\n<p data-start=\"43\" data-end=\"289\" data-is-last-node=\"\" data-is-only-node=\"\">What if a specific application requires higher force? There\u2019s no need to increase the pressure across the entire factory. Pressure boosters can locally increase force (up to four times) only where needed, while keeping the main line at 4 bar.<\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/section><section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_2 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3><strong>Future-ready technological solutions<\/strong><\/h3>\n<p>Many modern components are already designed to perform at their best at lower pressures. Through the SMC catalog available from Technology BSA, it is possible to access enabling technologies such as:<\/p>\n<ul>\n<li><strong>Optimized actuators:<\/strong> cylinders with reduced friction or properly sized bores to maintain the required force even at 4 bar.<\/li>\n<li><strong>ZL series vacuum generators:<\/strong> optimized to operate with a supply pressure of just 3.5 bar.<\/li>\n<li><strong>Angle seat valves:<\/strong> designed to operate at pressures as low as 3 bar.<\/li>\n<li><strong>High-efficiency blow nozzles:<\/strong> designed to maximize air impact while reducing volumetric consumption.<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h3><strong>A real success story<\/strong><\/h3>\n<p>The effectiveness of this approach is proven by real-world results. At SMC\u2019s Shimotsuma plant (Japan), the gradual adoption of the 4-bar standard led to a <strong>20% reduction in annual air consumption<\/strong> and a cut of <strong>12 tons of CO\u2082 emissions per year<\/strong>, without compromising production.<\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/section><section class=\"l-section wpb_row height_medium width_full\"><div class=\"l-section-h i-cf\"><div class=\"g-cols vc_row via_grid cols_1 laptops-cols_inherit tablets-cols_inherit mobiles-cols_1 valign_top type_default stacking_default\"><div class=\"wpb_column vc_column_container\"><div class=\"vc_column-inner\"><div class=\"wpb_text_column\"><div class=\"wpb_wrapper\"><h2>Reduce your plant\u2019s energy costs by up to 20%<\/h2>\n<p>Compressed air accounts for around 10% of industrial energy consumption, but it is often wasted due to excessively high operating pressures. The rule is simple: <strong>reducing pressure by 1 bar means cutting energy costs by 6\u20138%<\/strong>.<\/p>\n<p><strong>Technology BSA<\/strong>, in partnership with <strong>SMC<\/strong>, helps you meet the challenge of the <strong>\u201c4-Bar Factory\u201d<\/strong>. Through consumption analysis and the adoption of optimized technologies, we can help you reduce energy bills and CO\u2082 emissions without compromising machine productivity.<\/p>\n<h3><strong>Fill out the form to request a preliminary assessment with our specialists.<\/strong><\/h3>\n<\/div><\/div>\n<div class=\"wpcf7 no-js\" id=\"wpcf7-f7264-o1\" lang=\"it-IT\" dir=\"ltr\" data-wpcf7-id=\"7264\">\n<div class=\"screen-reader-response\"><p role=\"status\" aria-live=\"polite\" aria-atomic=\"true\"><\/p> <ul><\/ul><\/div>\n<form action=\"\/en\/wp-json\/wp\/v2\/posts\/8413#wpcf7-f7264-o1\" method=\"post\" class=\"wpcf7-form init\" aria-label=\"Modulo di contatto\" novalidate=\"novalidate\" data-status=\"init\">\n<fieldset class=\"hidden-fields-container\"><input type=\"hidden\" name=\"_wpcf7\" value=\"7264\" \/><input type=\"hidden\" name=\"_wpcf7_version\" value=\"6.1.7\" \/><input type=\"hidden\" name=\"_wpcf7_locale\" value=\"it_IT\" \/><input type=\"hidden\" name=\"_wpcf7_unit_tag\" 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aria-hidden=\"true\"><\/div>\n<\/form>\n<\/div>\n<\/div><\/div><\/div><\/div><\/section>\n","protected":false},"excerpt":{"rendered":"SMC\u2019s 4-Bar Factory can transform industrial plants by reducing energy consumption by up to 20%. &nbsp; Energy efficiency is no longer an option\u2014it is a strategic lever for industrial competitiveness. &nbsp; In today\u2019s industrial landscape, the transition toward sustainable production models is a top priority. &nbsp; With the European Union outlining a clear roadmap toward...","protected":false},"author":109,"featured_media":8225,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[30,34,35],"tags":[],"class_list":["post-8413","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automazione-industriale-en","category-partner-en","category-products"],"acf":[],"yoast_head":"<!-- This site is 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