How to Right-Size a Compressed Air System for Expanding Manufacturing Facilities
As manufacturing facilities grow, compressed air demand often increases alongside production. Across the Mid-South, many plants in Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) find themselves dealing with compressed air systems that were originally designed for smaller operations.
Over time, additional equipment, expanded production lines, and increased automation place new demands on compressed air systems. When systems are not properly resized to match growth, facilities can experience pressure instability, rising energy costs, and equipment strain.
Right-sizing a compressed air system ensures that airflow, pressure, and system capacity align with both current and future production needs.
Why Systems Become Undersized
Compressed air systems are often installed based on initial production requirements. As facilities grow, additional equipment is added without re-evaluating the system as a whole.
Common causes of undersized systems include:
Adding new production lines
Expanding facility footprint
Increasing automation
Running additional shifts
Adding pneumatic tools or equipment
Over time, these changes can push the system beyond its original capacity.
Signs Your System Is Too Small
Facilities operating undersized compressed air systems may notice:
Pressure drops during peak production
Equipment running inefficiently
Compressors operating continuously
Increased maintenance issues
Rising energy costs
These signs often indicate that the system can no longer meet demand efficiently.
Key Factors in Right-Sizing a System
Airflow Requirements (CFM)
The most important factor in system sizing is airflow demand, typically measured in cubic feet per minute (CFM).
Each piece of equipment using compressed air contributes to total system demand.
System Pressure Requirements
Different applications require different pressure levels. The system must maintain consistent pressure at all points of use.
Demand Fluctuation
Facilities with fluctuating demand benefit from systems that can adjust output dynamically, such as VSD compressors or multiple compressor setups.
Air Storage Capacity
Receiver tanks help stabilize pressure and manage demand spikes. Proper storage sizing is critical for system performance.
Planning for Future Growth
When resizing a system, it’s important to consider future expansion.
Facilities should evaluate:
Planned equipment additions
Production growth targets
Additional shifts or operating hours
Designing a system with future growth in mind helps avoid repeated upgrades.
The Role of System Configuration
Right-sizing often involves more than simply installing a larger compressor.
Effective system design may include:
Multiple compressors for redundancy
Variable speed compressors for efficiency
Properly sized receiver tanks
Improved piping layout
A balanced system provides both capacity and flexibility.
Avoiding Oversizing
While undersizing causes problems, oversizing can also lead to inefficiency.
Oversized systems may:
Cycle excessively
Waste energy
Increase equipment costs
Proper system design balances capacity with efficiency.
Why Professional Evaluation Matters
Determining the correct system size requires analyzing actual facility demand, not just equipment specifications.
A professional evaluation can help identify:
True airflow requirements
Pressure needs across the facility
System inefficiencies
Opportunities for improvement
This ensures the system is designed to operate efficiently under real-world conditions.
Supporting Growing Manufacturing Facilities
As facilities expand across the Mid-South, compressed air systems must evolve alongside production demands.
Right-sizing ensures:
Reliable airflow
Stable system pressure
Improved energy efficiency
Reduced maintenance costs
Proper planning allows facilities to support growth without compromising performance.
Compressed Air System Design from Process & Power
Process & Power helps facilities across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) design and optimize compressed air systems for both current operations and future growth.
📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500
🌐 https://www.processnpower.com
If your facility is expanding or experiencing compressed air performance issues, a system evaluation can help ensure your equipment is properly sized for long-term success.
