10 Essential Steps for Maintaining Your Pneumatic Systems

April 25, 2024
Cara merawat sistem pneumatik yang tepat - Bawalaksana ID

Pneumatic Systems are renowned for their ease of maintenance, with core components designed for high durability and minimal upkeep. However, regular maintenance is essential to ensure these systems operate efficiently and perform at their best.

Neglecting proper maintenance can lead to several serious issues, including:

  • Frequent blockages
  • Accumulation of water in components and air lines
  • Stretched or ruptured hoses due to dimensional changes
  • Damage to FRL devices, solenoid valves, and pneumatic cylinders
  • Product contamination from dust, bacteria, and moisture
  • Reduced energy efficiency due to air leaks
  • A range of other unpredictable problems

Regular maintenance of pneumatic components is essential, particularly in the industrial and manufacturing sectors.

Research from Deloitte shows that performing routine maintenance on tools and machinery can lead to the following benefits:

  • Reduce maintenance costs by up to 40%
  • Decrease downtime by as much as 70%
  • Increase overall equipment effectiveness by 25-30%

Given pneumatic components’ critical role in production processes, maintaining them is essential for maximizing efficiency and minimizing disruptions on the factory floor.

In this guide, the Bawalaksana team will cover comprehensive maintenance methods to help you keep your pneumatic systems in top shape.

Read Also: [Expert Tips] Top Mistakes to Avoid When Maintaining Pneumatic Systems
Aplikasi sistem pneumatik otomatis di industri by Metal Work
Industrial Applications of Pneumatic System Automation – Manufactured by Metal Work Pneumatic.

Why is Maintenance of Pneumatic System Components Necessary?

According to Plant Engineering, 76% of manufacturing companies worldwide implement preventive maintenance, which can reduce machine repair costs by up to 40%. The same principle applies to pneumatic systems—proper maintenance helps significantly lower maintenance costs.

While pneumatic components are designed for durability and long service life, they are still susceptible to various challenges, including:

  • Dust: Accumulation on FRL units, pneumatic cylinders, solenoid valves, and other moving parts can disrupt system performance.
  • Air Moisture: Excess moisture leads to corrosion and rapid wear, shortening the lifespan of components.
  • Poor Air Quality: Contaminated or dirty air can impair the functioning of cylinders and valves, diminishing overall system efficiency and product quality.
  • Air Leaks: These can result from hoses that have outlived their service life, low-quality products, or parts that do not meet industrial specifications. Cracks, ruptures, and loose connections at fittings can all contribute to air leaks.

If these issues are not promptly addressed, the damage could spread to other components, leading to accelerated wear, increased air leaks, and potential system failures.

Also Read: 6 Common Causes of Pneumatic Hose Failure and How to Prevent Them
10 Essential Steps for Maintaining Your Pneumatic Systems

Steps and Methods for Maintaining Pneumatic Systems

Daily maintenance and inspections are essential to ensure long-term efficiency and reliability of pneumatic systems. These practices help prevent downtime and sustain optimal operation. Below are key steps and methods for maintaining pneumatic systems:

Cleaning the Exterior of Pneumatic Equipment

Regularly clean the exterior of pneumatic components to remove dust, oil, dirt, and other contaminants. Use soft cloths, brushes, or dust removal tools to ensure thorough cleaning. 

Pay special attention to the air intake and exhaust channels on valves and cylinders to maintain unobstructed airflow, which is critical for smooth system operation.

Rilsan PA 11 PHL by Mebra Plastik - Bawalaksana ID - Selang tahan panas terbaik - Selang Pneumatic
Rilsan PA 11 PHL pneumatic tubing – Manufactured by Mebra Plastik Italia.

Replacing Worn or Damaged Components

Preventive maintenance, through scheduled component replacement, is critical to avoiding unexpected downtime.

We recommend replacing any components that are damaged, worn or have surpassed their service life, even if they appear to be in good working condition.

The following pneumatic components should undergo regular inspection and scheduled replacement:

  • Pneumatic hoses
  • Pneumatic cylinders
  • Solenoid valves
  • FRL units

Adopting a preventive maintenance strategy will protect your system from the risk of downtime, particularly during periods of increased production demand.

According to Viking Analytics, preventive maintenance is highly effective in reducing downtime for equipment with predictable failure patterns or when the cost of failure is relatively low.

Predictive maintenance is also effective for equipment with unpredictable failure patterns or when the cost of failure is significantly higher.

Read Also: 10+ Components of Pneumatic System You Need to Know
Berbagai jenis fitting dan konektor untuk sistem pneumatik by Metal Work
Various Types of Fittings and Connectors for Pneumatic Systems – Manufactured by Metal Work Pneumatic.

Routine Inspection of Pneumatic Hoses and Fittings

Regular inspections of pneumatic hoses, connectors, and fittings are imperative for upholding the entire system’s integrity.

When conducting inspections, carefully examine for loose, cracked, or broken components and listen for any hissing sounds that may indicate air leaks. Should any damaged or worn hoses be detected, it is advisable to replace them prior to system operation.

Additionally, the utilization of an Ultrasonic Acoustic Detector can aid in identifying high-frequency hissing sounds associated with air leaks.

We strongly recommend using high-quality pneumatic hoses that adhere to international standards. It is crucial to recognize that pneumatic hoses serve as the lifeblood of the system by supplying air to every component.

The rapid deterioration, cracking, or rupturing of hoses due to corrosive substances, high pressure, or extreme temperatures can significantly heighten the risk of system failure or downtime.

High Quality Air Treatments Units (FRL Units) by Metal Work Pneumatic
High-Quality Air Treatments Units (FRL Units) – Manufactured by Metal Work Pneumatic.

Cleaning and Maintaining the Air Service Unit

The Air Service Unit, also known as the FRL (Filter, Regulator, Lubricator), is a critical component requiring thorough attention.

The performance of the FRL unit can significantly impact the longevity of pneumatic valves and cylinders. This component functions akin to the human respiratory system, ensuring clean air delivery to the entire system.

Consequently, it is imperative to routinely inspect the cleanliness of the FRL unit, ensuring the absence of dust accumulation and the proper functioning of the lubricator.

Given its pivotal role in filtering air from dust and impurities, daily inspection of this device is essential. Dust and impurities ingressing into pneumatic devices can expedite the corrosion or malfunction of solenoid valves and pneumatic cylinders.

Silinder Pneumatik - Jenis dan Cara Kerjanya - Bawalaksana ID
Various Types of Pneumatic Cylinders (Linear & Rotary) – Manufactured by Metal Work Pneumatic.

Routine Maintenance of Pneumatic Cylinders

Pneumatic cylinders are crucial components that generate motion and require regular maintenance to ensure optimal system performance.

Extreme environmental factors, such as heat, humidity, and high usage cycles, can accelerate the wear and tear of seals and cylinder rods.

Neglecting regular maintenance can increase repair costs and potential system-wide operational disruptions.

Proactive maintenance of pneumatic cylinders is vital to prevent costly and severe downtime.

Here are some benefits of properly maintaining pneumatic cylinders:

  • Enhanced Performance and Lifespan: Regular maintenance improves the efficiency and extends the service life of pneumatic cylinders.
  • Cost Savings for the Company: Proper maintenance reduces the need to purchase new pneumatic cylinder units, which can cost millions of rupiah.
  • Early Problem Detection: Regular checks can identify issues early, preventing more severe damage.
  • Avoiding Unschedule Downtime: Timely maintenance helps avoid unexpected downtimes that could lead to significant cost overruns.

For a comprehensive guide, please refer to our article on How to Maintain Pneumatic Cylinders to Prevent Damage.

Lubricating Moving Parts

Regular lubrication of the moving parts in pneumatic components ensures smooth operation and prolongs the equipment’s lifespan.

Most pneumatic components vendors provide comprehensive guidelines and instructions for proper lubrication practices.

This routine maintenance helps prevent obstructions and rust on moving parts, ensuring optimal performance and reliability.

Kompresor udara untuk sistem pneumatik
Air Compressors for Pneumatic Systems.

Maintaining the Cleanliness of Air Compressors

Regular cleaning of air compressors and air lines is essential. Pipes, hoses, fittings, and connectors should also be inspected to ensure all components are intact and leak-free.

Allowing air leaks in the compressed air lines can lead to increased production costs of up to $38,776 annually and waste 20%-30% of the output generated by the air compressor.

If these leaks are not addressed, they can strain the air compressor and potentially damage other components within the pneumatic system. In short, air leaks can significantly inflate production costs and hinder operational efficiency.

Cara mengeluarkan air dalam sistem pneumatik
Pneumatic System Maintenance for Optimal Equipment Performance.

Removing Water Accumulation and Keeping Air Dry

A significant challenge faced by compressed air (pneumatic) systems is moisture and water accumulation.

Water can accumulate along pipes, pneumatic hoses, air service units, valves, and cylinders, moving in the same direction as the system’s air flow.

The presence of water can “wash away” lubricants in solenoid valves, cylinders, and other devices, making components more susceptible to corrosion, wear, and severe damage.

Additionally, moisture shortens the lifespan of pneumatic tubing, leading to dimensional changes that can result in stretching, cracking, or bursting.

To effectively remove water accumulation in pneumatic systems, consider the following methods:

  • Install Drain Valves and Water Separators: These components help manage and eliminate excess water from the system.
  • Regularly Remove Water at Critical Points: Ensure water is drained from high-risk accumulation areas, such as air storage tanks, FRL units, and drain valves.
  • Use Refrigerated Air Dryers or Desiccant Air Dryers: These dryers can effectively remove moisture from the air supply in environments with high humidity.

For more detailed information, please refer to our article, “How to Remove Water from Pneumatic Systems and Prevent Accumulation.

Regulating Air Pressure According to System Requirements

It is imperative to maintain air pressure within optimal parameters for pneumatic systems.

In industrial settings, pneumatic pressure typically falls within the range of 5-10 BAR (72 – 145 Psi / 500 – 1000 Kpa), as highlighted by Romanta Pinrih Linuwih, a specialist in Pneumatic Automation Systems at PT. Bawalaksana Central Industrial.

Regular monitoring of air pressure is essential to ensure compliance with these specified limits or the specific requirements of the system. Continuous monitoring during system operation is crucial. To streamline pneumatic air pressure monitoring, the implementation of an IoT-Based Real-Time Pneumatic Pressure Monitoring and Notification System is recommended.

Digital Flowmeter Devices for Industrial IoT by Metal Work Pneumatic - Bawalaksana ID
Digital Flowmeter Devices for Industrial IoT – Manufactured by Metal Work Pneumatic.

One of the most advanced tools for optimizing pneumatic systems is the Flowmeter by Metal Work Pneumatic. This device can be operated through a specialized FluxUp application, enabling real-time data access via an IO-Link interface with Bluetooth or Wi-Fi connectivity.

The Metal Work Flowmeter comes in five versions: Flux 0, Flux 1, Flux 2, Flux 3, and Flux 4, each designed to meet different needs. The critical functions of the Metal Work Flowmeter include:

  • Flowmeter: Measures both instantaneous and cumulative air flow rates.
  • Flow Switch: Triggers a response when air flow reaches a specified threshold.
  • Pressure Gauge: Monitors air pressure within the pneumatic system.
  • Pressure Switch: Responds to changes in air pressure.

Measuring energy parameters is crucial for effectively monitoring and analyzing pneumatic system performance. The collected data can be further analyzed to predict energy consumption trends and evaluate the system’s operational efficiency.

Implementing these measures will allow you to take action to boost the energy efficiency of pneumatic systems, ensuring optimal productivity on the factory floor.

With seamless integration into IoT-based technology and systems, Metal Work’s Flowmeter offers a superior solution for remote monitoring and real-time adjustments of pneumatic systems using smartphones, tablets, or computers.

See our previous article for a deeper dive into Enhancing Pneumatic System Energy Efficiency for Sustainable Manufacturing.

The benefits of optimizing pneumatic system efficiency - Bawalaksana ID
The benefits of optimizing pneumatic system efficiency.

Avoid Operating Pneumatic Devices Beyond Their Design Limits

Every component within a pneumatic system is carefully engineered to operate optimally within specific parameters, including pressure, temperature, and environmental conditions.

Take pneumatic hoses as an example.

Before production, industrial experts and R&D teams thoroughly research the materials, composition, and design of hoses to meet specific industry requirements. This process ensures the hoses are tailored to their intended applications, providing the ideal balance of durability, structure, and cost.

Pneumatic hoses are typically rated to withstand pressures 3-4 times higher at 23°C than their maximum operating pressure, a margin known as the “safety factor on working pressure.”

However, when the pressure or temperature exceeds—or even approaches—these limits, the risk of hose rupture or failure increases significantly.

Thus, it’s crucial to choose high-quality pneumatic hoses that are durable and precisely matched to your industrial specifications and needs. (Read: 11+ Best Heat-Resistant Hoses for High-Temperature Applications).

Addressing Malfunctioning Pneumatic Components

It’s essential to be aware that pneumatic components may exhibit abnormal behavior during operation, including excessive noise, unusual vibrations, or a sudden drop in performance.

When this occurs, it’s crucial to inspect the system promptly to identify the root cause. Once the issue is identified, it’s essential to perform the necessary maintenance to resolve it.

Addressing these concerns can help prevent unexpected breakdowns disrupting production and avoid costly downtime.

High Quality pneumatic parts and components by Metal Work Pneumatic
High-quality pneumatic parts and components – Manufactured by Metal Work Pneumatic.

Maximizing System Performance with Premium Spare Parts from Authorized Distributor

We presented a comprehensive manual on pneumatic system maintenance meticulously curated by the Bawalaksana team. The insights provided will assist in optimizing the efficacy and lifespan of your pneumatic systems.

We believe the knowledge imparted in this article will prove invaluable in refining your company’s maintenance protocols.

Our adept team strongly advocates for regular performance monitoring of pneumatic systems. We also emphasize utilizing superior, certified spare parts to guarantee uninterrupted operations and consistent production yields.

PT Bawalaksana Central Industrial is a reputable purveyor of industrial automation systems and spare parts. It is poised to collaborate with you to meet your maintenance and repair requirements.

As an authorized distributor, we furnish top-tier pneumatic hoses from Mebra Plastik Italia, cutting-edge automation components from Metal Work Pneumatic, and precision-engineered pressure gauges from Instruments To Industry (ITI).

We invite you to engage with our Sales Engineer team for excellent, globally accredited industrial wares and spare parts.

Please do not hesitate to contact our sales team for further information on products and services or to arrange a complimentary consultation.

Kindly click the consultation button below to explore your industry’s most optimal and productive solutions.


Romanta Pinrih Linuwih - Managing Director at PT. Bawalaksana Central Industrial - Square

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.

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