Designing an efficient compressed air system

Compressed air is an essential utility in industrial businesses to keep production moving. However, an efficient compressed air system is more than buying an air compressor. The layout, piping, storage, and treatment are key components to performance, energy efficiency, and long-term reliability.

Leading industrial businesses across Australia turn to Pilot Air. With more than four decades of experience, Pilot Air offers more than just equipment; we deliver complete compressed air solutions, from site diagnostics to tailored design, local manufacturing, and ongoing support.

Why a complete solution matters

Many businesses start by purchasing an air compressor, only to discover that poor piping layouts, undersized storage, or inadequate drying systems limit efficiency. A piecemeal approach will mitigate the value of compressor investment. Without a purpose-designed solution, businesses that rely heavily on the air compressor don’t maximise its energy efficiency and encounter inconsistent pressure, moisture problems, and costly downtime.

Pilot Air takes the guesswork out by offering end-to-end project management. Instead of dealing with multiple suppliers, industrial clients deal with one partner to deliver a system designed to meet current needs while allowing for future growth. This approach ensures that every component, from the compressor to the final air outlet, is customised for optimum performance.

Site diagnostics and customised design

Our technical team visits industrial facilities covering everything from automotive to food and beverage production, pharmaceutical and chemical industries, logistics and workshops. Each is unique in size, power, air needs and purpose. Pilot Air begins with on-site diagnostics to ensure the most suitable system, where our experts analyse air demand, pressure fluctuations, existing infrastructure, and future capacity needs.

Using qualified data, we design a system that solves current challenges and is tailored to the client’s operations. Whether that means introducing a closed-loop piping network for consistent pressure, upgrading to a rotary screw compressor for continuous duty, or integrating larger receivers to stabilise demand, every recommendation is based on operating conditions that suit the client facility.

Local production and a complete range of integrated products

One of Pilot Air’s strongest advantages is our local, Australian-owned, family-operated operations. From compressors and air receivers to Quickline piping and filtration systems, every component is built to our exacting standards and designed to integrate with the rest of the system.

This in-house capability means faster delivery times, consistent quality control, and systems engineered to work together from the start. Clients also gain peace of mind knowing that spare parts, servicing, and technical support are available locally, reducing downtime and ensuring reliability. Each system design is handled by a dedicated account manager who acts as your direct contact from start to finish.

Intelligent layout with piping, storage and air treatment built in

Energy costs are a significant expense in running a compressed air system. Poor layout or piping choices waste thousands of dollars annually. Pilot Air addresses this by designing efficient layouts that minimise pressure drop, use corrosion-resistant aluminium piping, and allow for easy future expansion.

Combining technical expertise with high-quality materials, we help industrial clients achieve lower running costs, stable air pressure, and longer equipment life. We design systems with the right-sized receivers to buffer demand and reduce compressor cycling. We integrate dryers and filters to guarantee clean, dry air, protecting tools, machinery, and finished products.

For industries like spray painting or precision machining, even small amounts of moisture or contaminants can ruin results. By including the right storage and treatment as part of the overall design, Pilot Air ensures air quality that meets industrial demands

Why industrial clients choose Pilot Air

When you partner with Pilot Air, a complete compressed air solution is backed by decades of expertise. Our clients choose us because we provide:

  • End-to-end service: From site analysis and design to installation and servicing.
  • Customised solutions: Tailored systems built around each client’s unique operations.
  • Local production: Australian-built compressors, receivers, and piping.
  • Integrated product range: Compressors, dryers, filters, tanks, and piping designed to work together.
  • Ongoing support: Preventive maintenance, spare parts, and technical advice from local experts.

Designing an efficient compressed air system is about partnership. Pilot Air’s unique ability to deliver complete, customised solutions is why many Australian businesses trust us as their long-term compressed air partner.

Experience the best in rotary screw air compressors

Pilot Air is one of Australia’s leading suppliers of rotary screw air compressors. Our team is qualified to conduct a diagnostic assessment and install the most suitable compressed air infrastructure with built-in scalability for your immediate needs. Pilot Air is proudly Australian-owned and independent, with onshore maintenance and service, skilled technicians, and an extensive spare parts inventory. Contact our team today.

The Pilot Air Team

Our compressed air experts are the best in the business. Committed to outstanding service delivery, our team and network of over 50 specialist technicians are with you every step of the way.

Compressed Air Products

We have Australia’s most extensive range of air compressor solutions, from high-performance models to portable and compact units. We also manufacture the latest air storage, air treatment and air distribution solutions. We offer a complete inventory of spare parts and on or off-site servicing and maintenance and can customise a complete compressed air solution for any business. 

Best suited for industrial applications to meet the ever-changing demands of the industry.

Rotary Screw
Compressors

All the reliability of a Pilot Air product, in a quiet package.

Silent Air
Compressors

Tailored for trade, professional or industrial applications.

Reciprocating Air
Compressors

Horizontal and vertical air receivers to complete a compressed air system installation.

Compressed Air
Storage

100% pure oil-free air, designed for applications where air quality is critical.

Oil-Free Air
Compressors

A range of products that offer safe, clean air, free from impurities.

Compressed Air
Treatment

Ideal for clients with small, specialist compressed air requirements.

Compact Air
Compressors

Efficient and easy to install, with high-quality components.

Compressed Air
Distribution

Perfect for noise sensitive environments where air demands are constant.

Portable Air
Compressors

Perfect for noise sensitive environments where air demands are constant.

Portable Air
Compressors

Complete solutions, including horizontal and vertical air receivers.

Compressed Air
Storage

Ideal for clients with small, specialist compressed air requirements.

Compact Air
Compressors

Frequently Asked Questions

What makes compressed air systems more complex than just buying a compressor?

A compressor is only one part of the equation. The system’s efficiency and reliability depend on proper layout, piping, storage, and treatment. Without these elements working together, businesses face problems such as pressure drops, moisture in the air supply, higher energy costs, and equipment downtime.

Why do leading Australian businesses choose Pilot Air?

Pilot Air has more than 40 years of experience providing end-to-end compressed air solutions. Industrial clients value the fact that Pilot Air not only supplies equipment but also offers site diagnostics, tailored design, local manufacturing, installation, and ongoing technical support.

How does Pilot Air help industrial customers improve efficiency?

Pilot Air works with clients to design intelligent layouts that reduce wasted energy, maintain consistent air pressure, and extend equipment life. By introducing features such as closed-loop piping, correctly sized receivers, and integrated dryers and filters, businesses achieve lower running costs and improved production reliability.

How does Pilot Air support industrial clients from start to finish?

Unlike dealing with multiple suppliers, customers work with one dedicated account manager who oversees the entire project. From on-site diagnostics to customised design, local manufacturing, installation, and servicing, Pilot Air manages every stage to ensure systems are built for current demands and future growth.

What role does local manufacturing play in Pilot Air’s service?

Being Australian-owned and operated, Pilot Air produces compressors, receivers, piping, and filtration systems locally. This means shorter delivery times, consistent quality control, and faster access to spare parts and servicing. Industrial clients also gain peace of mind knowing support is available nearby.

Why is air treatment important in compressed air systems?

Moisture and contaminants can damage equipment and compromise finished products. Pilot Air integrates dryers, filters, and treatment systems into designs to ensure clean, dry air. This is especially critical in industries like food and beverage, pharmaceuticals, spray painting, and precision machining.

What industries benefit most from Pilot Air’s expertise?

Pilot Air serves a wide range of industries including automotive, logistics, workshops, chemical and pharmaceutical manufacturing, as well as food and beverage production. Each facility receives a tailored solution based on its size, air demand, and operating conditions.

What are the long-term benefits of partnering with Pilot Air?

By providing integrated systems that are efficient, scalable, and locally supported, Pilot Air helps businesses reduce energy costs, minimise downtime, extend equipment lifespan, and maintain consistent production. Clients view Pilot Air as a long-term partner in achieving reliable industrial performance.

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