AIR SAVING CONTROL
90% energy savings on average

Intelligent Vacuum Regulation to Reduce Compressed Air Consumption


Compressed air is one of the most expensive utilities in industrial automation. In conventional Venturi vacuum systems, air consumption continues as long as vacuum is maintained — even when no additional energy is required to hold the part.

COVAL Air Saving Control (ASC) eliminates unnecessary compressed air consumption by regulating vacuum generation dynamically.

Energy savings: 60% to 97% depending on the application
Average savings: 90%

How Air Saving Control Works


ASC operates using a closed-loop vacuum regulation principle.

Phase 1 – Vacuum Generation
The Venturi pump generates vacuum until the predefined threshold level (L2 – typically 75%) is reached.

Phase 2 – Air Cut-Off
Once the target vacuum level is achieved:

  • The compressed air supply is automatically shut off
  • The non-return valve maintains vacuum
  • Air consumption drops to zero


If micro-leaks cause the vacuum level to drop below threshold (considering hysteresis), the system briefly reactivates compressed air to restore the target level.

Phase 3 – Release
The part is released via timed or external blow-off command.

This control logic ensures compressed air is used only when physically required.

Resulting savings

ASC energy savings are major as shown in the 2 examples below:

  • 80% savings when transferring a object after gripping.
  • 98% savings when clamping a object during an operation lasting 1 min.
    The investment generally pays for itself within a few months.

Energy Saving App

Calculate the savings you can generate with COVAL's ASC technology using the ENERGY SAVING APP available online.

Test Energy Saving App

Averages 90% Energy Savings

Smart Adaptation to Application Conditions

ASC automatically adapts to material characteristics.

Airtight Objects
ASC operates continuously in energy-saving mode.

Porous or Leaking Conditions
If excessive leakage is detected:

  • The system temporarily bypasses ASC
  • Production continues without interruption
  • Diagnostic feedback signals the anomaly

Once normal sealing conditions return, ASC mode is automatically restored.

This ensures both energy optimization and production continuity.

 

Why ASC Matters in Industrial Automation


Air Saving Control directly impacts:

  • Operating cost reduction
  • Compressed air system load
  • CO₂ footprint reduction
  • Vacuum stability
  • Predictable cycle times

It transforms vacuum generation from constant air consumption to intelligent demand-based regulation.

FAQ / Compressed Air Optimization