Designing a more efficient pneumatic system for automated packaging

In a high-throughput packaging machine, pneumatic performance depends on more than selecting a cylinder with enough theoretical force. The cylinder, valve island, tubing, air supply and control strategy must work as a complete system if the machine is to achieve its required cycle time consistently without using more compressed air than necessary.

That was the engineering challenge behind a new automated packaging application developed by BEUMER. The system required compact, repeatable pneumatic motion while also supporting efficient machine assembly and commissioning.

We worked with BEUMER from the early stages of pneumatic circuit development through to testing at its facility. Together, we reviewed the complete pneumatic system, including cylinder sizing, valve island configuration, tubing dimensions, air supply and control requirements.

Why system-level pneumatic design matters

A pneumatic circuit can contain correctly specified individual components and still perform poorly as a complete system.

A cylinder may provide sufficient theoretical force, for example, but restricted valve flow, long tube runs or pressure loss during peak demand can prevent it from completing its stroke within the required time. Conversely, increasing every component size to create additional design margin can add cost, installation volume and compressed-air demand without resolving the underlying constraint.

For the BEUMER application, we therefore considered the complete pneumatic path rather than treating the cylinders, valves and tubing as separate specification tasks.

Start with the required motion and load

Cylinder selection should begin with the task the mechanism must perform. This includes the load to be moved, the required stroke, the mounting orientation and the time available to complete each movement.

The calculation also needs to consider the pressure available at the actuator, not simply the nominal system pressure. Friction, acceleration, external resistance, mechanical alignment and end-of-stroke cushioning can all influence real-world performance.

Working with BEUMER, we supported cylinder selection using the application’s load and force requirements. We also considered the necessary cycle time and how the mechanism should respond if electrical power or compressed air was interrupted.

This application-led approach helps avoid two common specification problems: selecting a cylinder that struggles under dynamic conditions or oversizing the actuator and consuming more compressed air than the movement requires.

Match valve capacity to actual demand

The valve island must provide sufficient flow when the machine needs it. This becomes particularly important when several actuators operate at the same time.

Nominal valve-flow data is a useful starting point, but it does not always represent the pressure available at each actuator during a peak-demand event. The number of valve stations supplied through an inlet, the sequence of operation and the combined flow demand can all affect system response.

We worked with BEUMER to define the valve island configuration, size the valves and determine how the pneumatic supply should be distributed across the system.

This helped us balance two requirements: providing sufficient flow for consistent actuator response while avoiding unnecessary capacity that would add size, cost or complexity.

Bringing several valve functions together in a configured valve island also creates a more organized pneumatic architecture, reducing the amount of separate pipework and electrical connection required within the machine.

Size tubing for flow, distance and air volume

Tubing is an important part of the pneumatic circuit, yet it is often treated as a secondary decision.

Tubing that is too restrictive can create pressure loss and limit actuator speed. However, increasing the tube diameter is not always the answer. Larger or unnecessarily long tubing increases the internal volume that must be pressurized and exhausted during every cycle.

The correct choice depends on the actuator’s flow requirement, the distance between the valve and actuator, operating pressure, fitting and connection restrictions, the required motion time and the volume of air used during each cycle.

We reviewed the tubing dimensions and flow paths with BEUMER rather than applying a blanket oversizing rule. The aim was to provide the required actuator response while controlling unnecessary compressed-air volume.

Where possible, positioning valves closer to actuators can also reduce tubing volume and pressure loss. However, accessibility, environmental conditions and maintenance requirements must be considered alongside pneumatic efficiency.

Consider the complete compressed-air supply

Reliable pneumatic operation depends on the pressure, quality and condition of the compressed-air supply.

Even when individual components are correctly sized, restrictions or pressure fluctuations elsewhere in the system can affect machine performance. Air preparation, supply-line capacity, isolation, drainage and pipe routing must therefore be considered as part of the overall machine design.

As part of our work with BEUMER, we advised on the arrangement of the compressed-air supply and pneumatic lines, including the management of condensate within the system.

Important design considerations include the pressure available during periods of maximum demand, filtration appropriate to the application, potential low points where condensate could collect, provision for drainage, pipe and hose routing, isolation and depressurization, and access for inspection and maintenance.

Addressing these issues early can help protect pneumatic components, reduce avoidable pressure losses and make the finished system easier to maintain.

Define failure behavior during circuit design

Loss of electrical power or compressed air should be considered when the pneumatic circuit is first developed, not after the machine has been assembled.

The required response will depend on the mechanism and the machine risk assessment. An actuator may need to stop, retract, extend or hold a defined position. Where gravity, external loading or stored pneumatic energy could cause movement, additional control measures may be required.

During the design process with BEUMER, we considered how the pneumatic circuit should respond if either the electrical supply or compressed-air supply was interrupted.

At this stage, it is important to establish the position each actuator should adopt, whether a load could move if pressure is lost, whether stored pneumatic energy needs to be isolated or exhausted, what should happen when pressure or electrical power returns, and how maintenance personnel will isolate and verify the system state.

Defining these requirements early helps ensure the circuit architecture supports the intended machine behavior from the outset.

Test the complete pneumatic path

Calculations and component data provide the basis for a design, but the complete pneumatic system still needs to be assessed under representative operating conditions.

We visited BEUMER’s facility to review the assembled installation and confirm that the system followed the agreed pneumatic design. Together, we examined the layout, flow paths and control settings and made adjustments to support consistent operation.

A practical pneumatic test should consider supply pressure at rest and during peak flow, actuator movement and cycle time, repeatability across consecutive cycles, simultaneous actuator demand, cushioning and end-of-stroke behavior, leakage, responses to loss of electrical power or compressed air, and restart behavior.

Testing the complete machine can reveal issues that are difficult to identify from component data alone. Tube routing, fitting restrictions, exhaust conditions and control settings can all influence how the pneumatic system behaves in service.

Supporting BEUMER from design to testing

Through our collaboration with BEUMER, we developed a pneumatic system around the requirements of the automated packaging application rather than beginning with a predetermined component list.

Our work included reviewing the pneumatic circuit, supporting actuator and valve sizing, configuring the valve island architecture, assessing tubing dimensions and flow paths, advising on compressed-air supply and condensate management, considering the system’s response to interrupted power or air, and supporting testing at BEUMER’s facility.

This joined-up approach allowed the mechanical design, pneumatic architecture and control requirements to be considered together.

Practical lessons for packaging-machine designers

The project highlights five principles that can be applied to other automated packaging systems.

Specify the movement before selecting the component

Define the load, stroke, orientation, required motion time and intended failure behavior before choosing the actuator.

Check dynamic operating conditions

Assess the pressure and flow available during peak demand, not only the static supply pressure.

Treat tubing as part of the pneumatic circuit

Tube diameter, length, fittings and internal volume all influence actuator response and compressed-air consumption.

Define test criteria early

Agree how cycle time, repeatability, air use and system behavior will be assessed before final commissioning.

Review the assembled machine

Installation details and control settings can affect actual performance, even where the original calculations and component selections are sound.

Discuss your packaging machine application with us

If you are designing or updating a pneumatic system for packaging or material handling equipment, talk to us about your load, motion profile, cycle time, available pressure, installation constraints and required machine behavior.

We can help you assess the complete pneumatic path and identify how actuator sizing, valve configuration, tubing selection and system testing can support a more efficient and consistent machine design.