4 bar is the new standard for more durable machines 

Machine builders are used to selecting their pneumatic components in machines based on a working pressure of 7 bar. But by reducing the pressure to 4 bar, end users can reduce their energy costs by up to 29%: a powerful selling point for machine builders. To achieve this attractive result, more and more customers are turning to SMC's experts, who have both the know-how and the products to put this concept into practice.

The transition to a standard operating pressure of 4 bar is already taking place at some large manufacturing plants. Although it is not yet widespread, it is expected to gradually become the standard due to stricter regulations and increasing public pressure for a more sustainable industry. With that in mind, machine builders should prepare for a 4-bar future. By developing new machines now at 4 bar, they become pioneers in the industry. They can then not only capture a larger share of a rapidly emerging market, but also boost their corporate image. Although at first glance this change differs from the norm, working with the right knowledge partner can provide the right advice.

Cylinders: a step forward

When designing a new machine, it makes sense to start with the components that do the work: the pneumatic cylinders. These require a little extra attention. Two variables are essential: force and speed. In the case of force, it can be calculated theoretically using the formula "F=p x A. Where F is the force in Newton, P is the pressure in Pascal and A is the effective area of the piston in square meters.

Even easier is using SMC's Model Selection Software to create an optimal calculation for both horizontal and vertical applications. The software then selects the correct diameter of a pneumatic cylinder. The "oversizing" of cylinders is thus immediately a thing of the past. But, at a pressure of 4 bar, a large cylinder bore is needed to deliver the same force as at 7 bar.

A lack of space can cause a problem. What to do when a cylinder with a larger bore does not fit in your design space? A supplier of compact and lightweight actuators is the solution. SMC offers cylinders that are more compact and lighter than those of competitors. In addition, intermediate diameters are also available for this series of cylinders. Besides the diameters 32, 40, 50, 63 and 80 mm, SMC's engineers have developed intermediate diameters of 45, 56, 67 and 85 mm. 

This way you select the optimal diameter for the force required. Another solution to any lack of space is to use a different technology, such as a dual-force cylinder. Again, the expertise of a leading pneumatic component supplier can be helpful in specifying the optimal solution.

If the above solutions are not desirable, it is always possible to locally increase the pressure to achieve the required force. VBA pressure amplifiers can then provide the required pressure level in that local part of the application without increasing the machine pressure of 4 bar. This allows the existing dimensions of the cylinder to be maintained and eliminates the need for a larger diameter.

Blower air and vacuum units

For blower air and vacuum applications, higher pressure does not necessarily mean higher performance, quite the contrary. A high-efficiency nozzle can provide significant savings. This solution maximizes airflow efficiency, thanks to a more focused blowing impact. Through the Bernoulli effect, blowing power can be improved with 10%.

"We saw this recently at a customer who produces liquid detergent," illustrates Roy Schep, Manager of Energy Efficiency. "The company's bottle sorting machine contained 25 competitor air nozzles that consumed 22,441 euros of compressed air annually. After a machine analysis, we advised the customer to use our high-efficiency nozzles. These deliver the same blowing performance (impact), but with a smaller diameter, allowing lower input pressure. Lower air consumption resulted in savings of 6,183 euros per year, with a payback period of only 1.57 months. The same replacement took place on six other lines, achieving total annual savings of 37,098 euros."

Vacuum units also function most efficiently at a working pressure of 4 bar. "At this working pressure, SMC guarantees the vacuum pressure needed to safely hold the workpiece. Above this pressure, air (and money) is simply wasted and the vacuum unit loses efficiency. Increasing the pressure does not increase vacuum pressure - it just increases inefficiency.