Pressure drop is the difference between the compressor discharge pressure and pressure that comes to the actual user of the compressed air, for example, the laser cutting machine. 

Pressure drop is thus undesirable and is an indirect cost that results in higher electricity consumption and higher production price of the end goods. 

It occurs due to improper sizing of air treatment equipment and due to insufficient maintenance of the equipment. 

»A properly designed system should have a pressure drop less than 10%.«

According to the rules of good practice, a properly designed system should have a pressure drop less than 10% compared to the compressor’s discharge pressure, measured from the receiver tank output to the user (machine or tool).

The problem with pressure drop worsens during summer when the airflow and temperature are at highest. 

With higher temperatures in the summer months and increased humidity, more water comes into the compressed air system. Filter elements become saturated with contaminants even faster in the summer time when there is more humidity. 

»1 bar of pressure drop, needs of additional energy 7 to 8 %.«

Despite the fact that the filter element plays a useful role in the removal of compressed air pollutants, it’s saturation could be a problem since it will increase in time. 

The filtering efficiency of the saturated filter is much higher, since the pores of the filtering medium are narrower. 

This significantly increases the pressure drop in the system. 1 bar of pressure drop causes the need for 7 to 8 % of additional energy to drive the compressor.

As a result, the pressure drop increases and the compressor requires additional power, which means a significant increase of operating costs. 

Pressure drop in the filter element must be monitored and controlled through all times to detect it on time. 

Use a reliable pressure indicator and change filter elements regulary.

Selecting the right filters and maintaining them 

When selecting filters have in mind that they will gradually saturate and therefore need to be replaced. 

Wet conditions are undesirable for compressed air systems. Not only corrosion but also higher pressure drop appears.  Thoughtful choice of drying technology further depends on the required dew point. 

For stable quality and low cost filtration it is recommended to replace the filter element after aproximately 12 month of operation or when pressure drop exceeds recomended values for each model. For more info check the product data sheet.

Control pressure drop with reliable pressure drop indicators

Choose a reliable pressure drop indicator with an analogue or digital display of saturation level of the filter element. Some of the models of indicators come with an output for remote monitoring.

OMEGA AIR produces a range of pressure drop indicators.

Conclusion

Maintaining pressure drop within optimal limits is not just a technical detail — it’s a crucial factor in reducing energy consumption, extending equipment lifespan, and lowering overall operating costs. 

With proper system design, regular maintenance, and the use of high-quality filtration and monitoring solutions, pressure drop can be effectively managed. 

At OMEGA AIR, we offer reliable filtration products and pressure drop indicators engineered to help you achieve better system efficiency, long-term savings, and uninterrupted performance.

Check our offer or contact us for more information.