compressed air monitoring systems

In virtually every manufacturing facility in the world, in hundreds of industrial control applications, compressed air systems are used as power sources for tools and equipment. Most industrial facilities need some form of compressed air – from running a simple air tool to operating pneumatic controls.

Compressed air is an expensive medium; yet despite that, many compressed air systems are wastefully managed and with minimal system transparency. Capturing essential system performance data and monitoring critical air quality data is not only enlightening, but also enables future investments in compressed air systems to be fact-based and traceable.

Leaks waste energy and money.
This chart indicates the costs and energy loss associated with leaks. An undetected hole as small as 5mm can cost a plant €16,176 per year. Predictive leak detection and repair will result in substantial cost savings and system efficiency.

how are the leaks detected?

Our meter monitors air consumption to detect leakage areas in two ways

Method 1: when machine is in operation the meter compares the machine’s ideal air consumption to the actual air consumption. The difference indicates an air leakage.

Method 2: when machine is shutdown the meter continuously monitors the machine during shutdown. Any air consumption that is measured indicates an air leakage.
our meter can also monitor • Leakage per individual machine

Leakage per zones in a plant
Consumption per machine cycle
Consumption per shift
Consumption per zones in a plant
Verification of leak repair and system improvements
Dividing a plant into zones is key to leak detection In order for the meter to provide predictive maintenance information, a plant should be first divided into zones based on the number of fittings and potential leakage points. After sectioning a plant into smaller, more manageable zones, the meter is mounted in the supply line to the zone. The sensor will detect leakage areas based on the zone’s increase in air consumption over time or monitor air consumption when machines in the zone are shut down.

After a leakage area is detected, leak repair can occur quickly. The meter will target a leakage area by zone so that plant personnel can focus on a specific, smaller area, rather than search an entire plant for air leaks. With the zone identified, maintenance can quickly pinpoint the exact leak location and repair the leak. The best method for this is to use an ultrasonic acoustic detector and follow up with soap and water applied to the suspected leak.


we offer smart solutions

we discuss with you the details and condition of your compressed air network
we undertake to do a feasibility study
we offer a starter kit suitable for your requirements (if you want to start on a small scale)
we offer complete stand alone systems that can include monitoring of consumption, pressure, dewpoint, oil content, with or without wireless telemetry which can be controlled via a touch screen, or a PC in your office, or via the internet.

SIGMA Compressed Air Monitoring System

With the Sigma Compressed Air Monitoring System - a stand alone, autonomous and user friendy system - you can have the following benefits:

  • Continuous monitoring and measurement of air consumption, air flow, compressed air dew point, and air pressure (other parameters also possible) for instant diagnostics of problems & trends.
  • On line compressed air demand analysis
  • Easily integrated in to your existing installation and open with total flexibility to expand if necessary.
  • Direct point or remote monitoring at the office with optional touch screen or PC display.
  • Monitoring System can have up to 256 stations.
  • Savings on electrical energy consumption.
  • Increased service life of your equipment through continuous monitoring of compressed air dewpoint, flow rates and consumtion as well as condition maintenanance.

We cater for your network with simple or complex smart solutions and make the burden of looking after your compressed air, easy to handle.