Compressed air systems rarely remain as they were originally designed. As industrial facilities expand, add new zones, and stretch pipe networks, pressure instability moves from occasional nuisance to daily obstacle. Traditional control methods often fail to solve these issues in the long term.
That was exactly the challenge facing a major automotive manufacturer in Czechia, where persistent pressure drops and uneven supply across production zones were impacting overall compressed air performance.
In partnership with VSK PROFI, a certified AIRMATICS reseller, the plant deployed AIRMATICS AERO – a software platform built specifically for industrial air systems that have outgrown their original configurations.
The Problem: Imbalance Across Zones, Waste Across the System
The site operated a combination of four variable-speed compressors – 2 × 132kW and 2 × 45kW – supplying two production areas. One of these zones, located remotely, was especially prone to pressure drops and instability.
With growing demand and limited flexibility in the pipework layout, several key issues were identified:
- Uneven pressure distribution between core and remote zones
- Inefficient compressor coordination and frequent overcompensation
- Manual workarounds that increased energy waste
- A need for tighter integration with building management systems via MODBUS
- Limited visibility into real-time system performance
The site didn’t just need better monitoring. It needed intelligent control, capable of understanding and adapting to dynamic, real-world conditions.
The Solution: Adaptive Software for Real-World Systems
Rather than overhaul infrastructure, the facility selected AIRMATICS AERO to restore system-wide pressure stability and reduce energy waste, without physical redesign.
Led by Martin Palkovič of VSK PROFI, the team implemented AERO across the full compressed air network, integrating key modules to deliver fast, measurable results.
AERO: Real-Time Smart Control
At the heart of the solution, AERO ensured all compressors operated in coordination – responding to true, system-wide demand rather than isolated pressure drops. This real-time orchestration improved responsiveness while preventing unnecessary overcompensation.
Pressure Balancing: Dynamic Stability Across Zones
The Pressure Balancing software monitored multiple locations simultaneously, adjusting setpoints dynamically to maintain consistent pressure throughout the facility.
Key benefits included:
- Smoother pressure alignment between zones
- Reduced oversupply to remote areas
- Smarter load response across all compressor units
Zone Control: Smarter Sequencing Across the Network
With the network logically divided into operational zones, AERO determined which compressors should run and when. This ensured the right equipment was active only when needed.
This approach:
- Reduced unnecessary runtime
- Minimised energy use across low-priority areas
- Maintained optimal pressure in mission-critical zones
Edge-to-Cloud Connectivity: Local Control, Global Visibility
AERO’s connectivity extends control from the shop floor to the cloud:
- On-site diagnostics via local UI
- MODBUS RTU & TCP integration with existing SCADA/BMS systems
- Remote dashboards for multi-site analysis and long-term performance trends
The deployment of Aero ensures every stakeholder – from engineers to energy managers – has access to the right insights, whenever and wherever they’re needed.
The Results: Measurable Impact
Within months of deployment, the facility recorded:
- ⚡ 225,000 kWh/year in energy savings
- 💶 €18,000/year reduction in operating costs
- 🌍 138,900 kg of CO₂ emissions avoided annually
(Audit data with 80% confidence accuracy)
By addressing pressure balance and control inefficiencies, the site stabilised performance, reduced operational waste, and extended equipment life, all without needing to rebuild its infrastructure.
Built for Complexity. Ready for Growth.
AIRMATICS AERO is designed for industrial reality, not ideal conditions. Whether you’re working with legacy pipework, shifting layouts, or decentralised systems, it brings modern control and intelligence without disruption.
What it delivers:
- Balanced pressure without manual workarounds
- Lower runtime, energy use, and maintenance burden
- Smart sequencing and load control based on true demand
- Unified system visibility on-site and remotely
Delivered with Local Expertise
This project’s success reflects the strength of local support + smart software. VSK PROFI’s deep knowledge of the Czech industry ensured AERO was deployed with precision and tailored for the client’s unique environment.
Control the Pressure – Don’t Just React to It
If your compressed air system spans buildings, suffers from instability, or simply lacks visibility, AIRMATICS AERO provides the tools to take back control – intelligently, reliably, and efficiently.
Get in touch with VSK PROFI or AIRMATICS to explore how zone control and pressure balancing can unlock savings without starting from scratch.
Here are a few photos of the new installation, which is already up and running.
