We design and build compressed air installations for production halls, workshops, process lines and workstations. Each system is selected according to the actual flow demand, required air quality, environmental conditions and the planned future expansion of the system.
We have many years of experience in the construction of compressed air installations in industrial facilities. Our projects include both main distribution pipelines and extensive networks of air take-off points, as well as technical infrastructure components cooperating with the compressed air system.
We deliver compressed air installations tailored to plant operating conditions, process requirements and the expected standard of workmanship. We implement systems in various material technologies, including aluminium, stainless steel and PP plastic.
Below we present selected photos of completed installations. The gallery shows various pipeline routing options, outlet point solutions and the workmanship aesthetics in industrial and technical facilities.
A compressed air installation should be tailored to the process, not only to the floor area of the hall. A workshop has different requirements, an assembly line has different requirements, a production plant operating in shifts has different requirements, and an area requiring enhanced medium quality or resistance to chemical conditions has different requirements again.
A compressed air installation design should be based on process data, not on approximations. In practice, this means calculating the air demand balance, determining simultaneous receiver operation, the required air quality class, operating conditions and the plant development plan. This ensures that the installation is neither oversized nor undersized.
We collect data for each receiver: flow in l/min or Nm³/h, operating pressure, duty cycle and simultaneity factor.
We select a compressor or a multi-compressor arrangement with reserve capacity for load growth and safe operation.
We define the air quality class, filtration level, dew point and drying technology appropriate for the process.
We design pipelines, branches and outlet points to minimise pressure drops and enable quick connection of additional zones.
We can analyse compressed air demand, select a compressor, plan the network layout and indicate a solution tailored to your plant’s operating conditions.
There is no single universal parameter such as “which compressor for a pneumatic installation”. Selection always results from the flow and pressure balance. What matters is not only the sum of catalog demand values, but also how many receivers operate simultaneously and what the load profile looks like over time. That is why the same hall may require one screw compressor, two compressors operating in cascade, or a system with a standby unit.
At the selection stage, we analyse base flow, peak flow and a safe reserve. In industrial installations, the reserve should not be used to mask design errors. It should secure production growth, not compensate for leaks, undersized pipes or incorrectly selected outlet points.
Pipeline material selection affects installation durability, medium cleanliness, resistance to environmental conditions, ease of installation and the possibility of future expansion. That is why we select materials according to actual operating conditions, not solely according to purchase price.
CPP PREMA builds compressed air installations in aluminium, stainless steel and PP plastic. The choice of solution depends on operating pressure, temperature, chemical conditions, hygienic requirements, routing method, as well as the expected aesthetics and modularity of the system.
The answer to the question “what pipes should be used for a compressed air installation” can never be universal. In one hall, installation speed will be key, in another chemical resistance, and in another ease of cleaning and reduction of contamination risk. That is why we select materials based on function, not on a generic scheme.
Outlet points are not a minor installation detail. These are the locations that determine working convenience, operational safety and the quality of the medium delivered to the receiver. Properly designed branches reduce the risk of condensate carry-over, facilitate servicing and allow new workstations to be added without shutting down the entire installation.
In practice, properly planned outlet points simplify the everyday work of operators, reduce the length of working hoses and minimise the risk of overloading selected installation sections. This is an element that affects both workstation ergonomics and future operating costs, as well as the ease of expanding the entire network.
Compressed air quality is selected according to the process. Not every installation requires the same cleanliness class. For some applications, an industrial standard is sufficient, while for others very dry and very clean air is required, with limited content of particles, oil and moisture.
In practice, the reference point is ISO 8573, which classifies compressed air cleanliness with regard to solid particles, moisture and oil. This means that the installation design should specify not only the compressor, but also the required final result at the receiver: the air quality class, dew point, filtration level and the method of parameter control.
Dew point is not a marketing parameter. It is one of the key design parameters of a compressed air installation. If too much moisture remains in the system, corrosion, condensate and unstable operation of pneumatic components occur, and in some industries there is also a risk of product quality issues.
In practice, a commonly encountered level is a pressure dew point of approximately +3°C, achieved by refrigerant dryers. If the process requires drier air, adsorption drying and a lower dew point are usually applied, for example -20°C, -40°C or lower. This parameter must always be selected according to installation operating conditions and receiver requirements.
A compressed air receiver stabilises system operation, reduces pressure fluctuations and helps cover short-term increases in demand. However, one large tank is not always the best solution. In some systems, dividing the volume among several tanks or applying an additional buffer tank near a critical demand zone works better.
Receiver capacity selection always results from the demand profile, compressor control strategy, permissible pressure fluctuations and process requirements. A receiver tank cannot replace an incorrectly selected compressor, but it can significantly improve overall system stability.
Compressed air treatment is selected according to the required medium quality class and the type of process. A typical system may include condensate separation, pre-filtration, fine filtration, drying and additional treatment stages at stations with elevated requirements.
The leak tightness of a compressed air installation has a direct impact on energy costs, compressor operation and process stability. Leaks do not only increase bills. They also cause compressors to operate longer, increase the load on the air treatment system and accelerate wear of components throughout the system.
In practice, even a properly selected compressor and a correctly designed network will not deliver the expected result if the installation loses compressed air through joints, fittings, outlet points or uncontrolled network sections. That is why in both design and installation we pay attention not only to pipe diameter and material selection, but also to installation quality, sectioning logic, zone isolation capability and subsequent system operation control.
A well-designed pneumatic installation should be easy to monitor, not only quick to install. Both leak tightness at commissioning and the possibility of later diagnostics and rapid detection of loss locations are important, especially in multi-shift plants where even seemingly minor leaks can generate significant long-term costs.
If you want to identify where the installation is losing compressed air and which areas require improvement, see our leak audit offer. It is a practical first step before installation модернизация, system expansion or optimisation of operating costs.
Not every compressed air installation operates in a standard production hall. In many plants, aggressive chemical environments, high or low temperatures, outdoor operation, dust, explosive atmospheres and the risk of electrostatic charge accumulation must be taken into account.
In special environments, installation selection should include not only the pipeline material, but also route layout, connection type, seal selection, washdown resistance, contact with chemical media and compliance with the safety requirements applicable in the facility.
If an installation is to operate in a special environment, we do not apply universal solutions. Each such system requires a separate technical assessment. This also applies to planned expansion, because the new section must remain compliant with the requirements of the entire zone and process conditions.
A properly designed compressed air installation should not end with the current machine layout. It should allow for production growth, new outlet points, additional workstations and changes in hall organisation. That is why we apply logical zoning, sectional isolation, connection reserve and solutions that facilitate expansion without shutting down the entire installation.
Not every situation requires building an entirely new installation. Often, a better solution is to modernise part of the network, change the pipeline material, add drying, replace filtration, rebuild branches or divide the system into sections.
For compressed air receiver tanks, technical inspection authority requirements must be verified. Already at the concept stage, it is worth checking the vessel parameters, pressure and equipment documentation in order to properly plan commissioning and operation.
Installation instrumentation is equally important. Flow measurement makes it possible to see how much air the plant actually consumes, which sections operate unstably and whether increased demand results from production or from leaks. In a well-managed pneumatic installation, instrumentation is not an add-on. It is a cost control tool.
The cost of a pneumatic installation depends on several groups of factors. Route length alone is not sufficient for pricing. Flow rate, pipe diameters, pipeline material, number of outlet points, filtration level, required dew point, receiver type, route layout, installation accessibility and special conditions also matter.
A good pneumatic installation must be tailored to the process, predictable in operation and prepared for plant development. That is why at CPP PREMA we focus not only on installation itself, but on fully matching the solution to the customer’s working conditions.
A compressed air installation should not only be commissioned correctly, but also prepared for future servicing. That is why documentation, section labelling, service access, the possibility of isolating part of the network and the clear logic of the entire system all matter.
The scope of warranty, acceptance conditions and operational responsibility should always be defined in the offer, documentation and project-specific arrangements. This is more transparent and safer than declaring one rigid warranty model for all plants, industries and operating conditions.
If you are planning to build a compressed air installation, modernise an existing network or want to check whether your current system is operating optimally, the best place to start is a conversation with someone who designs and implements such solutions on a daily basis.
Contact our technical sales specialist. We will help you select the right pneumatic installation configuration, define compressed air demand, plan outlet points and choose solutions tailored to your production and plant development plans.
Senior Technical Sales Specialist
Phone
+48 661 611 317
E-mail
blazej.sokulski@cpp-prema.pl
Flow rate, pressure, air quality class, required dew point, pipeline material, outlet point layout, operating conditions and expansion plan must all be defined.
You should sum the demand of all receivers, take into account their simultaneity of operation and add a rational design margin. It is best to rely on manufacturer data and measurements.
It depends on base flow, peak flow and the plant’s operating mode. In some facilities one compressor is sufficient, while in others a multi-unit arrangement with reserve capacity is better.
No. With greater demand variability, shift operation or high process criticality, a multi-compressor arrangement is often a better solution.
There is no single best material for all facilities. Selection depends on pressure, temperature, process chemistry, medium quality, installation method and planned expansion.
Yes. Outlet points affect ergonomics, pressure drops, the risk of condensate carry-over and the ease of future installation expansion.
The reference point is ISO 8573, which classifies compressed air with regard to solid particles, water and oil.
No. The required air quality always depends on the process, the receiver and the effects of possible moisture or contamination of the medium.
It depends on the process and operating conditions. In many standard systems, approximately +3°C is used, while more demanding applications require lower values, for example -20°C or -40°C.
When the installation requires moisture control, protection against condensate and a stable dew point appropriate for the process and ambient conditions.
It depends on the structure of the plant and the nature of the demand. In some systems one tank is sufficient, while in others an arrangement of several tanks or a buffer tank is more beneficial.
A buffer tank helps stabilise pressure and reduce the effects of short, high demand peaks in a selected part of the installation.
Very important. Leaks increase compressor load, raise energy costs and make it more difficult to maintain stable operating parameters.
Yes. Instrumentation makes it possible to distinguish real process consumption from losses and to plan system modernisation and expansion more effectively.
Yes. It is worth providing connection reserve, sectioning, the possibility of adding branches and space for further measurements from the outset.
Zone classification, component selection, method of execution, grounding and compliance of the solutions with the requirements for the given potentially explosive atmosphere.
Yes. It can affect the choice of pipe material, seals, anti-corrosion protection and the durability of the entire system.
This should not be assumed automatically. Requirements must be verified for the specific receiver tank, its parameters and the manufacturer’s documentation.
The air source, air treatment, pipeline material and diameters, number of outlet points, installation conditions, route accessibility and special requirements.
When the main problem concerns selected sections, pressure drops, moisture, lack of measurements, poor branch layout or lack of space for straightforward expansion.
