{"id":8674,"date":"2026-04-02T09:30:56","date_gmt":"2026-04-02T07:30:56","guid":{"rendered":"https:\/\/www.technologybsa.com\/?p=8674"},"modified":"2026-04-02T09:53:18","modified_gmt":"2026-04-02T07:53:18","slug":"compressed-air-digitalization-from-analogue-pneumatics-to-the-smart-factory","status":"publish","type":"post","link":"https:\/\/www.technologybsa.com\/en\/compressed-air-digitalization-from-analogue-pneumatics-to-the-smart-factory\/","title":{"rendered":"Compressed Air Digitalization: from Analogue Pneumatics to the Smart Factory"},"content":{"rendered":"

SMC \u00b7 Industrial Digitalization<\/span><\/h2>\n

Compressed air is the fourth utility in manufacturing. In most plants it is still managed reactively: visual inspections, fault-driven maintenance, no real visibility into consumption. Integrating digital technologies into existing pneumatic systems changes this logic.<\/span><\/p>\n<\/div><\/div>

The most affected sectors include automotive assembly lines, electronic component manufacturing and any industrial process using rotary tables or robotic systems \u2014 contexts where cable routing has historically been one of the main operational bottlenecks.<\/p>\n<\/div><\/div><\/div><\/div>

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What Is Digitalization Applied to Compressed Air?<\/h2>\n

Compressed air digitalization<\/strong> consists of integrating smart sensors, digital actuators, fieldbus systems and wireless connectivity into existing pneumatic processes, transforming physical parameters \u2014 pressure, flow, temperature, humidity \u2014 into readable, recordable and actionable data in real time.<\/p>\n

The process follows three distinct phases: monitoring<\/strong> (real-time data acquisition and visualisation), control<\/strong> (parameter adjustment via KPI feedback loops), optimisation<\/strong> (historical analysis, predictive maintenance, energy efficiency and CO\u2082 footprint reduction).<\/p>\n<\/div><\/div>

The most affected sectors include automotive assembly lines, electronic component manufacturing and any industrial process using rotary tables or robotic systems \u2014 contexts where cable routing has historically been one of the main operational bottlenecks.<\/p>\n<\/div><\/div><\/div><\/div>

Key Benefits<\/span><\/h3>\n

\u2192 Data-driven operational decisions<\/strong>
\n\u2192 Reduced operational costs<\/strong>
\n\u2192 Structured predictive maintenance<\/strong>
\n\u2192 Measurable energy efficiency gains<\/strong>
\n\u2192 Scalable and autonomous operations<\/strong>
\n\u2192 Lower CO\u2082 footprint<\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/section>

Three Levels of Digitalization: Where Does Your Plant Stand?<\/h2>\n

Compressed air digitalization does not require a single, disruptive technology overhaul: SMC has identified three digitalization maturity levels, each with a defined upgrade path and measurable results.<\/span><\/p>\n<\/div><\/div>

01 – Minimal or No Digitalization<\/strong><\/h3>\n

Manual pressure and flow control. Visual monitoring only. No IO-Link, no fieldbus.<\/p>\n

Recommended upgrades \u2192<\/strong><\/h4>\n
    \n
  • ISE20\/ZSE20 \u00b7 Series ITV<\/li>\n
  • Main line filter Series AFF<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div>

    02 – Intermediate Digitalization<\/h3>\n

    Active digital pressure and flow control, IO-Link, fieldbus. Wireless and cloud not yet in place.<\/p>\n

    Next steps \u2192<\/strong><\/h4>\n
      \n
    • Fieldbus unit EX600<\/li>\n
    • Position sensor D-MH1<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div>

      03 – Advanced Digitalization<\/h3>\n

      Wireless, cloud, OPC UA for vendor-agnostic data exchange. Full plant visibility including remote sites.<\/span><\/p>\n

      Key technologies \u2192<\/strong><\/h4>\n
        \n
      • EXW1 wireless + OPC UA<\/li>\n
      • AMS20\/30\/40\/60 \u00b7 VPX400<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/section>
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        <\/div>

        Data Instead of Inspections: What You Can Monitor<\/h2>\n

        SMC IO-Link products enable accurate real-time data collection from every point of the pneumatic circuit.<\/span><\/p>\n<\/div><\/div>

        Pressure<\/strong><\/h3>\n

        Real-time monitoring and remote regulation<\/strong><\/p>\n

        Remote detection of excessive pressure drops, parameter configuration without manual intervention, electronic out-of-range signalling.<\/p>\n

        ISE20\/ZSE20 \u00b7 ITV \u00b7 PSE<\/strong><\/p>\n<\/div><\/div>

        Actuator Position<\/strong><\/h4>\n

        Wear detected before unplanned stoppage<\/strong><\/p>\n

        Continuous monitoring of actuator speed and positional variation to schedule maintenance intervention before failure.<\/p>\n

        Series D-MH1<\/strong><\/p>\n<\/div><\/div><\/div><\/div>

        Flow & Temperature<\/strong><\/h4>\n

        Flow anomaly detection and consumption benchmarking<\/strong><\/p>\n

        Real-time leakage detection, machine-to-machine air consumption benchmarking, adaptive flow regulation per individual process.<\/p>\n

        PF3A \u00b7 PFCA7<\/strong><\/p>\n<\/div><\/div>

        Cycle Counting<\/strong><\/h4>\n

        Scheduled maintenance, not reactive repair<\/strong><\/p>\n

        Automatic cycle counting via the EX600 built-in function. Wear-part replacement scheduled before failure, not after.<\/p>\n

        Series EX600<\/strong><\/p>\n<\/div><\/div><\/div><\/div>

        Humidity & Condensate<\/strong><\/h4>\n

        Dryer protection and air quality assurance<\/strong><\/p>\n

        Continuous dew point and condensate level monitoring. Early warning of dryer malfunctions before downstream damage occurs.<\/p>\n

        Series PSH<\/strong><\/p>\n<\/div><\/div>

        Leakage Detection<\/strong><\/h4>\n

        Localised monitoring on critical components<\/strong><\/p>\n

        Localised air consumption in actuators monitored and flagged before reaching critical levels, with continuous comparison against commissioning benchmarks.<\/p>\n

        PF2M7 \u00b7 PF3AmH<\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/section>

        From Standalone to System: SMC Digital Architecture<\/h2>\n<\/div><\/div>

        The SMC digital architecture is an integrated environment where all pneumatic systems and processes are connected \u2014 with real-time data collection, analysis and management, including across multiple sites. Wireless connectivity and OPC UA<\/strong> data exchange extend the architecture further, with an open, vendor-agnostic design.<\/p>\n

        The EXW1 Series<\/span> \u2014 a compact wireless system with an integrated OPC UA server \u2014 and the Air Management System (AMS)<\/span> are the key components for reaching this level of integration.<\/p>\n<\/div><\/div><\/div><\/div>

        OPC UA: the open standard for Industry 4.0<\/strong><\/h3>\n
          \n
        • Vendor and software platform independent<\/li>\n
        • Data access and sharing across global sites<\/li>\n
        • Closed network or Internet with built-in security<\/li>\n
        • Easily expandable architecture<\/li>\n
        • Scalable machine-to-machine communication (M2M)<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
          <\/div>

          What Changes for Your Technical Team<\/span><\/span><\/h2>

          Fewer unplanned stoppages, lower energy waste, greater process control \u2014 for maintenance managers, facility managers and plant operators.<\/span><\/p>\n<\/div><\/div><\/div><\/div><\/div>

          Predictive Maintenance<\/span><\/span><\/h3><\/div><\/div>

          Automatic cycle counting, operational data history, actuator wear monitoring. Planned interventions, not fault-driven repair.<\/span><\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div>

          Process Optimisation<\/span><\/span><\/h3><\/div><\/div>

          Historical data analysis surfaces slowdowns and inefficiencies. Localised pressure drops and flow anomalies become visible and actionable.<\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div>

          Energy Management<\/span><\/span><\/h3><\/div><\/div>

          Maps energy consumption across the entire plant. Isolates or reduces pressure in non-productive areas. Supports CO\u2082 reduction initiatives.<\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div>

          Quality Control<\/span><\/span><\/h3><\/div><\/div>

          Monitoring temperature, pressure and actuator speed enables early detection of anomalies before they impact finished product quality.<\/strong><\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/section>

          Assess Your Plant’s Digitalization Level<\/h2>\n

          Technology BSA is an authorised SMC distributor in Italy. Our technical team can support you in assessing your pneumatic system’s current digitalization level and defining the most suitable upgrade path.<\/span><\/p>\n

          Contact our experts for a personalised technical assessment.<\/strong><\/h3>\n<\/div><\/div><\/div>\n