Pneumatic equipment longevity is not accidental, it is engineered. Pneumatic systems are the backbone of countless industrial operations — from manufacturing and packaging to material handling and agriculture. These systems are prized for their simplicity, speed, and cost-effectiveness, but they also face constant stress from contaminants, pressure fluctuations, and wear.
According to IMI Industrial Automation (IMI Norgren), with proactive practices, there are three proven practices can significantly extend the life of pneumatic equipment and reduce costly downtime.
By focusing on air quality, maintenance discipline, and pressure control— and couple that with selecting the right pneumatic components —you can move from reactive repairs to long-term reliability.
LET'S SEE HOW!
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1. Control Contamination by Selecting the Right Filter
Clean air is the lifeblood of any pneumatic system. Contaminants such as water, dirt, dust, and oil in compressed air can accelerate wear, cause corrosion, and lead to premature failure of valves, cylinders, and other components.
How IMI Industrial Automation helps:
IMI Norgren offers a wide range of air preparation units, including:
IMI’s modular approach allows systems to be tailored precisely to operational requirements—protecting downstream components without sacrificing performance.
Selecting the correct filter grade for your application is critical. Over-filtration can restrict airflow, while under-filtration leaves sensitive components exposed.
Good filtration not only preserves internal components but also improves system efficiency — keeping your pneumatic equipment running reliably over the long haul.
Even the best filters can only do so much if they aren’t maintained. Filters collect contaminants over time, and their effectiveness diminishes — which can lead to pressure drops and additional strain on your system.
Here are some general replacement intervals suggested:
General purpose filters: Every 6–12 months
Coalescing filters: Every 6 months
Vapor removal filters: After ~1,000 hours of use
IMI Industrial Automation Maintenance Advantages:
Pressure drop indicators, integrated on both IMI Norgren Excelon® and Excelon® Plus General Purpose and Coalescing filters, signal when replacement is needed with a visual alert.
Automatic and electronic drains remove accumulated moisture without manual intervention, reducing corrosion risk.
Modular FRL designs make servicing faster, minimizing downtime during maintenance intervals.
Routine maintenance isn’t just about replacing parts on a calendar; it’s about responding intelligently to performance indicators so your equipment stays clean and efficient.
3. Regulate Pressure — Don’t Just Maximize It
Many operators mistakenly equate higher pressure with better performance. In reality, excessive pressure increases wear and accelerates component failure — and it wastes energy.
To manage pressure effectively:
Less strain on valves and cylinders helps avoid the unnecessary wear and tear. By maintaining optimal—not maximum—pressure, systems operate more efficiently, components last longer, and energy consumption is reduced.
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Following these three fundamentals — controlling contamination, adhering to maintenance schedules, and regulating pressure — shifts your approach from reactive repairs to proactive reliability. Clean, dry, properly regulated air keeps pneumatic equipment operating efficiently and reduces unplanned downtime and maintenance costs.
Bonus Insight: Don’t Forget Air Quality AND Lubrication
Outside of Norgren’s core three, other best practices further protect your system:
Ensure high air quality by using dryers and water separators to keep moisture out of lines. Poor air quality increases wear on seals and internal components.
Lubrication, where applicable, reduces friction and component wear. The right lubricator and lubricant help pneumatic parts move smoothly and last longer.
💡 Conclusion 💡
Pneumatic systems don’t wear out — they’re worn out. By prioritizing clean air, scheduled maintenance, and proper pressure control, you’ll safeguard your equipment’s performance and longevity.
Leverage IMI Industrial Automation products, such as Excelon® FRLs, precision regulators, and high-efficiency filtration solutions, and manufacturers can dramatically extend equipment life, reduce unplanned downtime, and improve overall operational efficiency.
Integrating these proven practices into your operational strategy isn’t just good maintenance — it’s smart business.
INTERESTED IN LEARNING WHAT SPECIFIC PRODUCTS CAN HELP YOU EXTEND THE LIFE OF YOUR PNEUMATIC EQUIPMENT?
We are happy to HELP!
With over 70 years of experience, The Knotts Company has a dedicated Pneumatic Team here for you. Combined with the right products, we can ensure your pneumatic systems continues to perform reliably today, tomorrow, and beyond.
Investing in the right air preparation and control solutions TODAY can save you costly repairs LATER!
LEARN MORE HERE: Knotts Pneumatic Assemblies - Air Management Assemblies (Filter/Regulator/Lubricator, lockout systems)