Pneumatic systems have been an essential part of industrial processes for many years. They utilize compressed air to power various automated machines and equipment, making production processes faster and more efficient. These systems are widely used in many industries and manufacturing sectors, including food and beverage, automotive, electronics, chemical, transportation, packaging, agriculture, construction, air brakes, automatic doors, and more.
Pneumatic systems work by converting compressed air into mechanical motion through pneumatic cylinders. These cylinders use the force of compressed air to move a piston back and forth. This motion is then used to power various tasks in production lines.
One advantage of using a pneumatic system is its simplicity. These systems are relatively easy to install and operate, requiring minimal maintenance compared to other systems. They are also cost-effective, as compressed air is readily available and inexpensive compared to different energy sources.
In this article, the Bawalaksana team will discuss in detail what a pneumatic system is, its advantages, the components involved, and how to maintain it.
Table of Contents
What is a Pneumatic System?
Pneumatic systems are a type of technology that employs compressed air as a medium to produce mechanical motion. Various industries and manufacturing sectors have widely used this technology to facilitate repetitive tasks quickly, hygienically, safely, and efficiently.
The term “pneumatic” is derived from the Greek language, where the word “pneuma” means “moved or played by means of air; of or pertaining to air or gases,” or “of the wind, belonging to the air,” or “blow, wind, breath, or inhaled air.”
Over time, “pneumatic” has been defined as applying compressed air to generate mechanical motion.
In a previous article, we explained the history and evolution of pneumatic technology and its fundamental principles.
Advantages of Pneumatic Systems
Pneumatic technology is widely used in systems that require mechanical movement due to its numerous advantages. It is one of the most cost-effective, safe, and easy-to-maintain options for industrial automation.
This section will discuss the four critical advantages of pneumatic systems.
Safety in Operation
Firstly, pneumatic devices are very safe to operate because they rely on compressed air as their primary energy source. This compressed air is obtained for free using an air compressor.
Additionally, the air pressure required to operate these devices is relatively low, ranging from 5-10 BAR (72-145 Psi / 500-1000 Kpa), which ensures safety during operation.
Furthermore, pneumatic systems do not pollute the air during operation, making them eco-friendly.
This feature is essential in industrial settings where air pollution can cause severe health and environmental.
In summary, pneumatic systems are safe and environmentally friendly automation devices that operate on a free and easily accessible energy source.

Flexibility Towards Technology
Pneumatic devices exemplify a high degree of flexibility intertwined with advanced technology, making them particularly suitable for contemporary manufacturing and industrial applications.
As illustrated above, the EB80 Island Valve is a modular valve engineered for pneumatic systems. It facilitates the simultaneous control of multiple pneumatic actuators. Integrating this device optimizes airflow, enabling precise movement management within the pneumatic system.
This module is capable of seamless connectivity with a Programmable Logic Controller (PLC), thereby enhancing the implementation of sophisticated automation processes.
Furthermore, the valve module can record critical data, such as pneumatic cylinder response times and usage cycles, while also supporting predictive maintenance.
In the context of Industry 4.0, technological flexibility within automation systems has become paramount. The integration of pneumatic devices with digital technology empowers industrial automation systems to function with increased efficiency and effectiveness.
Real-time monitoring via computers, tablets, or smartphones facilitates continuous oversight and enhances operational responsiveness.
Easy to Maintain
Pneumatic devices are widely recognized for their robustness, ease of maintenance, and prolonged lifespan. They are crafted using durable components to withstand wear and tear and require minimal upkeep.
However, to ensure the pneumatic system’s seamless operation, it is crucial to regularly inspect the cleanliness of the devices and provide a constant supply of air pressure. This helps prevent hindrances in the system’s functioning and ensures that it operates smoothly and efficiently.
Additionally, high-quality lubricants and filters are recommended to ensure the longevity of pneumatic devices. Maintaining and caring for pneumatic devices can improve performance, reduce downtime, and lower maintenance costs.

Energy Efficiency and Environmentally Friendly
Despite often being criticized for their low energy efficiency, pneumatic systems can be made more efficient by implementing the following measures:
- Selecting an appropriate compressor for its efficient operation under the intended workload.
- To ensure the device’s effective operation, choosing pneumatic components of the appropriate size is essential. This includes selecting the right size and type of pneumatic cylinder, which should neither be too large nor too small. Doing so can avoid putting excessive load on the air compressor.
- Regular maintenance is important to ensure the smooth operation of your equipment. This includes removing any dust or other contaminants that have accumulated over time.
- Ensuring the pneumatic hoses are of appropriate length to prevent any pressure drops.
- When selecting industrial pneumatic hoses, choosing those that can handle high workloads without cracking or breaking is essential.
In summary, pneumatic systems are safe, flexible, and environmentally friendly as they do not cause air pollution when the system is operating.
Our article, 4 Things That Are Not Disadvantages of Pneumatic Systems, explains the pneumatic systems’ advantages.
Main Components of Pneumatic System
The industrial pneumatic system comprises various complex parts, although they do not differ much from those present in typical pneumatic devices.
A few of the primary components of the pneumatic system for industries are as follows:
- Air Compressor
- Refrigerated Air Dryer
- Air Reservoir Tank
- Pneumatic Hose
- Solenoid Valve
- Pneumatic Cylinder
- Controller / Hand Lever
- FRL Unit
- Fittings

The pneumatic system is widely used to convert compressed air into mechanical motion. It consists of four crucial components that work together to regulate and maintain the system’s operation.
Air Compressor
The air compressor is the first component of the system. It takes in air from the surroundings and compresses it into pressurized air. This compressed air is then directed to the pneumatic cylinder via the hose.
Pneumatic Hose
The Pneumatic Hose, an industrial-grade hose, is primarily used to transfer pressurized air from the compressor to the Pneumatic Cylinder. This hose is designed to withstand high-pressure applications and is commonly used in industrial settings.
Pneumatic Cylinder
The pneumatic cylinder is another essential component that converts pressurized air into mechanical motion. Based on their motion, two types of pneumatic cylinders are used in the industry: rotary pneumatic and linear pneumatic cylinders.
The operation of the pneumatic cylinder also varies depending on the kind of motion.
Solenoid Valve
The fourth component, the solenoid valve, controls the piston movement of the pneumatic cylinder. It allows for the extension or retraction of the cylinder’s piston. The solenoid valve is also crucial for connecting the system with technology, sensors, and Programmatic Logic Controllers (PLCs).
It is important to remember that despite the high durability of pneumatic components, proper maintenance is still required for all devices.
Our article, The Components of the Pneumatic System, explains the pneumatic system’s components and vital devices.

How Pneumatic System Works
In the world of automation, pneumatic systems play a significant role in converting compressed air into mechanical motion. These systems use an Air Compressor to supply compressed air that is then directed to the Pneumatic Cylinder and Solenoid Valve via the Pneumatic Hose.
The solenoid valve regulates the airflow’s speed and direction when entering the pneumatic cylinder, allowing precise control over the generated mechanical motion.
According to industry expert Romanta Pinrih Linuwih, Pneumatic Automation Systems in industries usually operate at a pressure range of 5-10 BAR (500-1000 Kpa / 72.5-145 Psi).
The working principle of the pneumatic system can be broken down into several steps.
Compressing Air
The air compressor absorbs and compresses air from the atmosphere. The compressed air is then directed to the Refrigerator Air Dryer or stored directly in the Air Reservoir Tank.
Removing Air Moisture
The Refrigerated Air Dryer is a tool that removes moisture from the air, resulting in dry air. This device can rapidly cool the air to 3°C (37.4°F), known as the Pressure Dew Point (PDP).
When the air reaches this temperature, the water present in the air condenses, drips, and becomes water. The drip water is discharged, while the dry air is directed to the Air Reservoir Tank.
Storing Air in the Reservoir Tank
The compressed air that is free of moisture from the Refrigerated Air Dryer can be reserved as an energy source in the Air Reservoir Tank. The Air Reservoir Tank can distribute the stored pressurized air to all pneumatic devices with the help of pneumatic pipes or hoses.
Distributing Pressurized Air
Pressurized air is channeled to all pneumatic devices through Pneumatic Hoses, including Air Filters, Solenoid Valves, and Pneumatic Cylinders.
Filtering Air from Dust and Contaminants
The pressurized air directed to pneumatic components must first be filtered to remove dust and contaminants using an FRL (Filter, Regulator, Lubricator).
The FRL not only filters the air but also regulates air pressure and applies lubrication by delivering oil mist to the pressurized air channel. The FRL unit supplies air to all pneumatic devices, such as Solenoid Valves, Pneumatic Cylinders, Air Tools, and others.
Controlling Air Flow and Speed
The air supply’s flow and speed adjustment are necessary through Solenoid Valves. This will allow the Pneumatic Cylinder to move as per the system’s requirements.
Generating Mechanical Movement with Pneumatic Cylinders
Pneumatic Cylinders are crucial in converting compressed air into mechanical motion (either linear or rotational). These components generate mechanical movement that can be utilized for various tasks in the production line, including lifting or moving objects, cutting, packaging, sealing, and other functions.
The video below shows various components of the pneumatic system and their working principles briefly:
Suppose you desire to obtain a thorough understanding of this system’s functioning. In that case, we suggest visiting our article How Pneumatic Systems Work and the Main Components Used, which elaborates on how pneumatic systems operate and their primary components.
How to Maintain the Pneumatic System
Pneumatic systems are widely recognized for their ease of maintenance. Their primary components have been engineered to attain exceptional sturdiness.
Nevertheless, it is still essential to conduct routine inspections and replace components periodically to guarantee the system’s optimal performance. Here are some ways to keep a pneumatic system in good condition and some factors to keep in mind when performing maintenance:
- Regularly clean pneumatic devices to remove dust, oil, and other contaminants.
- Inspect pneumatic hoses daily to ensure no loose, cracked, broken, or air leaks.
- Replace worn components to avoid system failure or energy waste.
- Lubricate moving parts of the pneumatic system to ensure smooth operation and extend the lifespan of components.
- Routinely maintain the FRL unit to ensure the air supplied to the system is clean and dry. Remember to check the availability of oil in the FRL unit, as this device also lubricates the air channels leading to the Solenoid Valve and Pneumatic Cylinder.
- For system sustainability, use standard industrial pneumatic hoses. Non-standard pneumatic hoses can cause system failure due to easy cracking or breaking.
- Adjust and monitor air pressure at all times while the system is operating. The recommended air pressure is 5-10 BAR (72 – 145 Psi / 500 – 1000 Kpa).
- Turn off the pneumatic system when not in use to reduce operational costs.
Consider the points above to ensure the pneumatic system’s effectiveness, longer lifespan, and reduced downtime. For a more detailed explanation, visit our article How to Maintain the Pneumatic System.

Easy-to-Adapt Automation System with Technology
Pneumatic systems have undergone significant changes and advancements from the 19th century to the modern era.
Since its inception, the device has been digitized and made accessible to the general public. These systems have proven to be an economical solution for automation systems requiring linear motion.
Furthermore, with the ever-evolving technology, pneumatic systems have become an essential component of the Industrial Internet of Things (IIoT).
Sensors can be equipped on almost all pneumatic system equipment and components, from connectors, air filters, and pneumatic cylinders to pneumatic hoses. This makes information processing for pneumatic systems more accurate and manageable.
Modern pneumatic systems now have built-in diagnostic sensors that can monitor operating temperature, current voltage, and even the number of usage cycles.
This innovation offers a broad space for pneumatic systems to adapt to technology and develop more rapidly. This is one of the significant advantages of pneumatic technology, making it the best choice for manufacturers relying on automation systems in their production processes.
By using these sensors, manufacturing management can process all available data to improve productivity and perform preventive maintenance to avoid downtime.

Implementation of Pneumatic Systems to Enhance Productivity and Cost Efficiency
As detailed in this article, pneumatic technology presents a cost-effective solution for automation systems requiring mechanical movement. Its increasing popularity stems from its ease of maintenance and exceptional flexibility to integrate with modern technologies.
Pneumatic systems are vital connectors between technological advancements and practical applications, providing reliable automation solutions that expedite and optimize production processes.
These systems are ideal for modern manufacturing environments, enhancing production scalability and economic efficiency.
Adopting new systems in an industrial context can be a formidable challenge. However, the rapid evolution of technology today allows for more manageable solutions to the diverse challenges industries face.
At PT Bawalaksana Central Industrial, we are committed to being your trusted partner in implementing pneumatic systems. We adhere to best practices that ensure reliable performance, sustainable operations, and optimized return on investment.
We are proud to be the official distributor of Mebra Plastik Italia, renowned for its high-quality pneumatic hoses. Additionally, we represent Metal Work Pneumatic, a leading manufacturer of various pneumatic system components, including:
- A comprehensive range of pneumatic actuators
- Solenoid valves and valve modules compatible with PLC integration
- Pneumatic fittings for standard, automatic, quick-connect, compression, and other applications
- FRL units are designed to deliver clean and dry air
- V-lock systems for pneumatic and mechatronic automation
Each product we supply is accompanied by complete certification, ensuring compliance with the stringent standards and regulations applicable across various industrial sectors, particularly in food-grade pneumatic systems.
With a team of experienced engineers boasting over 7 years in the field, we are well-positioned to be your premier partner for implementing pneumatic automation systems across diverse industries.
We invite you to connect with our professional team to explore how modern pneumatic technology can enhance economic efficiency and profitability in your operations.
Click the consultation button below to receive tailored recommendations for pneumatic automation solutions in the era of Industry 4.0, and boost productivity on your factory floor today.

Romanta Pinrih Linuwih
Pneumatic Automation Systems Expert
This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.