What is pneumatics?
Pneumatics is the use of compressed air to transmit force and movement in machines and industrial systems. A compressor generates the compressed air; via air treatment — filters, dryers and pressure regulators — the air is conditioned and led to the consumers. Because air is compressible, the system responds quickly and is self-protecting in the event of temporary overload: the air absorbs the shock rather than responding rigidly. No oil leaks into the process, which makes pneumatics suitable for food, pharmaceutical environments and applications that need to be cleanable. This makes pneumatics a reliable choice for simple and repetitive movements with a high cycle frequency.
What are pneumatic components?
Pneumatic components are the parts used to build a compressed air installation: from air treatment and control valves to actuators, hoses and sensors. A correctly assembled system starts with dimensioning each component based on working pressure, flow rate and application. If you choose a component that is too small, pressure drops and slower cycles will result; if you choose too large, you will pay unnecessarily for air consumption and compressor capacity.
A complete pneumatic system consists of the following main components:
- Air treatment: filter regulators (FRL units), pressure regulators, dryers and oil mist lubricators. Dimension based on flow rate and dew point. View the full range of air treatment units for the right configuration per environment.
- Control valves: 3/2 and 5/2 solenoid valves for single-acting and double-acting cylinders respectively; valve manifolds for modular, compact control of multiple axes. Choose NAMUR valves for direct mounting on the actuator.
- Actuators: pneumatic cylinders (ISO standard, compact, guided), grippers and rotary actuators. The cylinder bore determines the force at a given pressure; the stroke determines the range of movement. View the range of pneumatic cylinders for your application.
- Hoses and tubing: the air hose connects all components and partly determines the flow in your system. Hose diameter and length are matched to the required flow rate; a hose that is too narrow or too long will immediately cause pressure drop. View the range of air hoses for the right version per pressure and medium.
- Fittings and couplings: push-in fittings, quick couplings and plug-in connectors connect hoses and valves leak-free and pressure-tight.
- Measurement and monitoring components: pressure sensors, flow meters, end position switches and IO-Link sensors for real-time monitoring and energy management.
Always choose pneumatic components based on working pressure, flow rate, medium and environmental requirements such as temperature, corrosion resistance and cleanability. Not sure about the dimensioning? Our pneumatic specialists will calculate it for you.
What are pneumatic fittings?
Pneumatic fittings are the connecting elements used to join hoses, tubes and valves in a leak-free and pressure-tight manner. They allow compressed air lines to be quickly assembled, disassembled and reconnected without tools or air loss. Choosing the right fitting largely determines the reliability of your entire installation: an incorrect or worn fitting is one of the most common causes of leakage and increased energy consumption.
The most commonly used types of pneumatic fittings:
- Push-in fittings: fast tool-free assembly, suitable for standard compressed air hoses in machine building and automation.
- Compression fittings: higher pressure resistance for rigid tubing (PA, nylon, copper). Choose these when higher vibration resistance is required.
- Quick couplings: allow hoses and tools to be disconnected quickly without pressure drop at disconnection. Applicable for pneumatic tools and changeover stations.
- Swivel fittings: prevent torsion and kinking at moving hose connections on rotating shafts or carousels.
- Stainless steel fittings: for food, washdown and corrosive environments; smooth contours minimise dirt accumulation.
Always pay attention to the thread type (BSPP, BSPT or NPT) and the sealing principle to prevent leakage. An incorrect fitting is one of the most common causes of compressed air loss in an installation.
How does a pneumatic system work?
Compressed air flows from the compressor via the air treatment unit to the control valves. These valves determine the direction and timing of the movement. The air then travels via the air hose to the actuator — a cylinder, gripper or rotary motor — which delivers the mechanical force. Pressure in bar determines the force; flow in l/min determines the speed. Fittings and couplings connect all components in a leak-free and pressure-tight manner.
Pressure, hose diameter and valve width must be matched to each other as a system. A hose diameter that is too small, an undersized valve or too low a network pressure causes pressure drops, slower cycles and higher air costs. Conversely, oversizing leads to unnecessarily high air consumption. Correct dimensioning is therefore the foundation of an energy-efficient and trouble-free system.
What is the difference between pneumatics and hydraulics?
Both systems convert pressure into mechanical force, but the medium and application areas differ fundamentally:
| Property |
Pneumatics |
Hydraulics |
| Medium |
Air (compressible) |
Oil (incompressible) |
| Force |
Up to approx. 50 kN at standard pressure |
Very high, hundreds of kN |
| Speed |
+ High, fast response |
- Slower, more precisely controllable |
| Positioning accuracy |
- Limited without positioner |
+ High |
| Environment |
+ Clean, food-compatible |
- Requires leak-free oil management |
| Maintenance |
Air treatment (filter/dryer) |
Oil treatment and leak control |
Choose pneumatics for fast, repetitive movements in clean or humid environments with limited force requirements. Choose hydraulics for very high forces and precise positioning, such as in heavy pressing or lifting applications. Not sure? Our specialists will advise you based on your process conditions.
Where can you save energy in your pneumatic system?
Compressed air is a relatively expensive energy carrier: generating it consumes electricity and leaks increase compressor load directly. The most savings can be achieved here:
- Leak detection and repair: even small leaks in fittings or hoses significantly increase compressor energy consumption. Repair them immediately.
- Pressure optimisation: lower the network pressure to the minimum your process requires. Every bar lower saves approximately 7% in compressor energy.
- Correct dimensioning: oversized cylinders, excessively long air hoses or undersized valves cause pressure drops and excessive air consumption.
- Reduce blow-off: replace unnecessary blow-offs with directed jets or vacuum; use quiet blow-off nozzles with low air consumption.
- Air treatment: a good dryer and filter prevent condensation and wear, reducing breakdowns and premature component replacement.
Request a pneumatics audit to map your savings potential and implement concrete reductions.
In which sectors is pneumatics used?
Machine building and automation: pneumatic cylinders and grippers handle gripping, positioning and transport in pick-and-place installations. Guided cylinders and adjustable cushioning patterns increase repeatability; quick exhaust valves shorten cycle time.
Food industry: stainless steel cylinders, hygienic fittings and IP69K-rated components withstand intensive cleaning. Oil-free compressed air in accordance with ISO 8573 prevents product contamination. Quick-release fittings with smooth contours minimise dirt accumulation.
Process automation: pneumatic actuators drive control valves with fail-safe spring return; NAMUR solenoid valves provide standardised mounting directly on the actuator without additional brackets or hoses.
Pneumatic tools: handheld air tools are light, spark-free and deliver continuous power without overheating. A correctly dimensioned FRL unit keeps performance consistent and extends tool service life.
Packaging and logistics: high-speed cylinders and valves handle sorting, stacking and sealing with high repeatability. Vacuum systems with ejectors grip boxes, bags and trays reliably, even with porous materials.
Always select cylinder, valve, air hose and fittings as a system: the combination determines pressure, speed and reliability. Request component advice from our pneumatic specialists for the right choice per application.
Frequently asked questions
What does the word pneumatics mean?
The word derives from the Greek 'pneuma', meaning 'wind' or 'breath'. In engineering, it refers to applications using compressed air for control and actuation. You will encounter it in terms such as pneumatic cylinder, pneumatic valve and compressed air system.
What is the minimum air treatment required for reliable operation?
At minimum, a filter and pressure regulator (FR unit) are needed to remove contamination and prevent overpressure. Add a dryer in environments with high humidity or low temperatures to prevent condensation in lines and valves. A lubricator is only required for components that need lubrication; do not use lubrication if your actuators are designed for oil-free operation.
When should I choose pneumatics instead of an electric actuator?
Choose pneumatics for fast, repetitive movements with a fixed end position, high cycle frequency and environments that are clean or humid. Choose an electric actuator when you need precise intermediate positioning, variable speed or precise force control, or when no compressed air network is available.
