The pipes are too small for the airflow. Pressure at the compressor is fine but drops significantly by the time it reaches the point of use.

What you'll see

Good pressure at the compressor, low pressure at the machines. The longer the pipe run, the worse it gets. Specific reference: for a 60 kW compressor producing 10,000 Nlpm, a 40mm pipe is adequate up to about 50 meters. For runs up to 1,500 meters, you need 80mm pipe.
Before you assume this is the problem

Verify there are no clogged filters or closed valves between the compressor and the point of use causing an artificial restriction.

See all causes of pressure drop →

How to diagnose

  1. Measure pressure at compressor and at point of use

    Install gauges at both ends. Run the system at normal demand. The difference is your pressure drop. Modern target: maximum 0.1 bar total. Old standard: maximum 0.7 bar (10%). If yours is above 1 bar, the piping is too small.

    Result: Large drop from compressor to point of use = piping problem.

How to fix it

  1. Upgrade to larger piping

    Replace undersized sections with larger diameter pipe. Install the main header as a ring/loop so air reaches every point from two directions -- this effectively halves the pipe length and dramatically reduces pressure drop.

Common mistakes

Don't increase compressor pressure to compensate for piping losses. You're spending energy to push air through a restriction. Fix the restriction instead.

Parts & tools

Larger piping. Pressure gauges for before/after measurements.

Review safety precautions before starting →

This issue can also cause

  • High Energy Use Excessive power consumption or unexpectedly high electricity bills, often caused by control problems, air leak...