HOW WE EQUIPPED A COMPLETELY NEW 11-HALL COMPLEX WITH A CUSTOM-DESIGNED COMPRESSED AIR NETWORK
A new construction project is the perfect opportunity to get a compressed air system right from the start. No compromises due to existing piping, no detours around old structures, and no limitations imposed by what’s already in place. Just a clean slate—and the responsibility to design it right the first time.
For this project, we were commissioned to provide a turnkey compressed air system for an entirely new industrial complex consisting of 11 buildings. From the climate-controlled compressor room to the final outlet in the farthest building: everything was custom-engineered, professionally installed, and delivered fully operational.
THE PROJECT: 11 HALLS, ONE COMPRESSED AIR SYSTEM, NO COMPROMISE ON PRESSURE DROP
The core of the assignment was clear but demanding: provide reliable compressed air at the correct pressure in each of the 11 halls, with the proper safety quick-connect couplings at every workstation—and ensure that the pressure drop across the entire piping network is minimal. The latter may sound obvious, but in practice it is one of the most underestimated challenges in compressed air projects.
Why Pressure Drop Is So Important
Pressure drop is the difference in pressure between the compressor and the farthest outlet in the piping system. Every meter of pipe, every bend, every coupling, and every filter creates resistance—and thus a pressure loss. If that loss is too great, the compressor must operate at a higher pressure to compensate for it. And every additional bar of working pressure results in an average increase of 7% in electricity consumption.
For a system that spans 11 halls, accurately calculating pipe diameters, pipe runs, and the number of tap-off points is not a luxury—it’s a direct energy savings measure that pays for itself many times over in thousands of euros over the system’s lifespan.
THE CONFIGURATION: COMPACT, COMPLETE, AND CUSTOM-DESIGNED
The complete technical configuration
| Component | Type / Specifications | Position |
|---|---|---|
| Screw compressor | Kaeser SM16T | Main compressor, 11 kW, with built-in refrigeration dryer |
| Control System | Kaeser Sigma Control | Monitoring, pressure control, fault monitoring |
| Compressed Air Filter | KE Net Filter with Eco-Drain | Oil filtration, automatic condensate drainage |
| Pressure vessel | Galvanized 500-liter | Pressure buffering, stabilization of peak air demand |
| Condensate Treatment | Aquamat CF6 | Oil/water separation, environmentally safe condensate discharge |
| Pressure-maintaining valve | Kaeser DHS 4.0 | Constant minimum pressure in the pipeline network |
| Pipeline Network | Custom-Sized Steel Pipes | Compressed air distribution throughout 11 halls |
| Dispensing Points | Prevost Safety Shortcuts | Safe, fast, and ergonomic connection |
| Compressor Room | Air-conditioned | Controlled temperature for optimal performance |
Are you already saving as much as you can?
SK Compressor Service inspects your compressed air system using professional ultrasonic equipment. You will receive a comprehensive leak report that includes locations, estimated losses, and priority rankings.
FROM AN EMPTY NEW CONSTRUCTION HALL TO A FULLY OPERATIONAL COMPRESSED AIR NETWORK
Step 1 — Design and Calculation
Before the first pipe was installed, we drew up the complete piping plan. For each hall, we determined the expected air consumption, calculated the pipe length, and specified the diameter. The pipe layout was designed so that the pressure drop at the farthest outlet would remain within the standard—even during simultaneous use in multiple halls.
Step 2 — Climate-Controlled Compressor Room
The compressor room was designed as a fully climate-controlled technical space. Ventilation, climate control, and appropriate acoustic measures ensure that the Kaeser SM16T operates under optimal conditions—summer and winter. A well-climate-controlled compressor room significantly extends the system’s service life and reduces the risk of malfunctions.
Step 3 — Installation of the compressor unit and peripheral equipment
The Kaeser SM16T was installed and electrically connected. The KE filter with Eco-Drain, the galvanized 500-liter pressure tank, the Aquamat CF6 condensate treatment unit, and the Kaeser DHS 4.0 pressure-maintaining valve were installed and interconnected.
Step 4 — Piping Through the Halls
Using a scissor lift, the piping system was expertly installed along the roof structures of all 11 halls. The steel pipes were neatly secured to the roof beams—neatly, professionally, and according to the pre-calculated plan. In each hall, a tap was installed at the correct height and position, equipped with a shut-off valve and a Prevost safety quick-connect coupling.
Step 5 — Pressure Test and Acceptance
After installation was complete, the entire piping system was pressurized and tested for leaks. Each outlet was checked individually. Following a successful pressure test, the system was handed over to the customer—complete with documentation of the piping layout, the calculations performed, and the Sigma Control settings.
THE RESULT: 11 HALLS, ONE RELIABLE COMPRESSED AIR NETWORK
| Aspect | Result |
|---|---|
| Number of halls provided | 11 halls, each with its own dispensing point |
| Pressure drop across the network | Minimum — calculated individually for each section |
| Safety at Dispensing Points | Prevost Safety Quick-Release Coupler at Any Point |
| Condensate Treatment | Environmentally Safe with Aquamat CF6 |
| Minimum pressure guaranteed | Via Kaeser DHS 4.0 Pressure-Maintaining Valve |
| Compressor Room | Fully climate-controlled |
| Completion | Turnkey, including pressure testing and documentation |
The complex is now fully operational for the use of pneumatic tools, machinery, and other compressed air outlets in all halls. The system is sized to meet current air demand and designed with sufficient capacity to accommodate future growth—ensuring that increased usage will not lead to capacity issues or higher operational loads.
WHY COMPANIES CHOOSE SK COMPRESSOR SERVICE FOR NEW COMPRESSED AIR PROJECTS
A new construction project offers a single opportunity to get it right. SK Compressor Service provides the expertise to make the most of that opportunity—from the initial design to final completion.
- Custom-designed — We design every compressed air network based on actual consumption, pipe length, and pressure class. Not a one-size-fits-all solution, but a custom-designed system that does exactly what it’s supposed to do.
- Turnkey from A to Z — Compressor room, compressor unit, peripheral equipment, piping network, discharge points, and commissioning: we take care of everything.
- Official Kaeser Dealer — Direct access to genuine Kaeser parts and the manufacturer's warranty. Learn more about Kaeser compressors.
- Safety Built In — Prevost safety quick-connect fittings at every dispensing point as standard — not as an option.
- NEN-3140 certified — All electrical connections are installed and documented in accordance with the standard.
- Energy-efficient design — Thanks to proper sizing, the compressor operates at the lowest possible pressure — which directly reduces your energy bill.
When is the best time to install compressed air lines in a new construction project?
As early as possible in the construction process—ideally as soon as the steel structure is in place and the roof is sealed. This allows pipes to be run along roof beams and structural elements before walls are finished and equipment is installed. This significantly reduces installation time and prevents pipes from having to run visibly through rooms later on.
How is a compressed air network designed to minimize pressure drop?
The calculation takes into account the air consumption per outlet, simultaneous use, the length of the piping from the compressor to each outlet, the number of bends and fittings, and the desired minimum working pressure. Based on this, the optimal diameter is determined for each section of piping. SK Compressor Service performs this calculation as standard before a single pipe is even installed. Learn more about installing compressed air piping.
What is the advantage of a Kaeser DHS pressure-maintaining valve?
The DHS pressure-maintaining valve ensures that a minimum pressure is always maintained in the piping system—even when the compressor starts up or during periods of temporarily reduced capacity. Without this valve, the pressure drops briefly during startup, which leads to reduced performance of pneumatic tools. With the DHS 4.0, the working pressure at every outlet is always stable and consistent.
Why Prevost shortcuts and not a cheaper alternative?
Prevost is the international industry standard for safe compressed air connections. The safety lock prevents a hose from unexpectedly disconnecting under pressure—a real danger with cheaper couplings that lack a lock. In a workplace where multiple people work with compressed air on a daily basis, this is not a minor detail but a basic requirement. Furthermore, Prevost couplings are extremely durable and do not need to be replaced after just a few years of intensive use.
Why choose Geberit Mapress as a piping system?
Geberit Mapress is a press-fit connection system that creates a completely leak-proof connection without welding or soldering. This makes it ideal for compressed air: installation is faster than with traditional piping, no open flames are required in the production area, and the connections can be tested immediately after installation. The system is also highly expandable—which is convenient if your production grows in the future.
Can SK Compressor Service also take over the maintenance of this system?
Yes. After installation, SK Compressor Service offers a customized maintenance contract —tailored to the type of compressor, operating hours, and usage. Preventive maintenance prevents breakdowns and keeps the warranty on the Kaeser compressor fully valid. You will receive a service report after each service visit.
Free advice
Are you already saving as much as you can?
SK Compressor Service inspects your compressed air system using professional ultrasonic equipment. You will receive a comprehensive leak report that includes locations, estimated losses, and priority rankings.
