Designing a Compressed Air System That Grows with Your Facility
Many compressed air systems are designed to meet today’s needs—and only today’s needs. As facilities expand, add equipment, or change processes, those systems are stretched beyond what they were built to handle. The result is higher energy costs, pressure instability, and frequent fixes that never quite solve the problem.
At Gordon Air Compressor, we encourage facilities to think about compressed air as a long-term system, not a single piece of equipment. Designing with growth in mind saves money, reduces disruption, and keeps production moving as demands change.
Start with How Air Is Used, Not Just How Much
Growth planning starts with understanding how compressed air is actually consumed across the facility.
Key questions include:
Which processes rely on air continuously?
Which machines use air intermittently?
Where are peak demand points?
How often does demand spike unexpectedly?
Knowing how air is used helps avoid oversizing or undersizing equipment as the facility evolves.
Leave Room for Capacity Without Overspending
Designing for growth doesn’t mean buying the largest compressor available. It means leaving room to expand intelligently.
Smart capacity planning may include:
Selecting compressors that can operate efficiently at partial load
Designing piping that can handle higher future flow
Allowing space for additional compressors or storage
Planning electrical capacity for future equipment
This approach avoids costly redesigns later.
Piping Design Matters More Over Time
Piping that barely meets today’s demand often becomes a bottleneck as usage increases.
Growth-ready piping:
Minimizes pressure drop
Uses proper pipe sizing
Reduces unnecessary bends and restrictions
Allows easy expansion for new drops or equipment
Correct piping design protects performance as demand grows.
Storage Helps Manage Future Demand
Air storage plays a critical role in handling growth. As more tools or machines come online, demand spikes become more frequent.
Additional or properly placed storage:
Buffers sudden increases in air usage
Stabilizes system pressure
Reduces stress on compressors
Delays the need for larger equipment
Storage is often one of the easiest ways to support expansion.
Plan Air Treatment with Expansion in Mind
Dryers and filters are frequently overlooked when planning for growth. As airflow increases, air treatment equipment must keep up.
Planning ahead includes:
Selecting dryers with capacity headroom
Designing filtration that can be expanded
Ensuring drains can handle increased condensate
Proper air treatment protects both current and future equipment.
Avoid Band-Aid Solutions
As systems grow, it’s tempting to apply quick fixes—raising pressure, adding small compressors, or bypassing problem areas. These short-term solutions often create long-term inefficiencies.
Designing for growth focuses on:
System-wide performance
Long-term reliability
Predictable operating costs
Fixing the system correctly once is almost always more cost-effective than repeated temporary solutions.
Flexibility Is the Real Goal
A growth-ready compressed air system is flexible. It adapts to changing demand without constant rework.
Flexibility comes from:
Proper equipment selection
Thoughtful layout
Allowing space and capacity for expansion
Understanding how air demand may change over time
This flexibility protects both productivity and budget.
Build a System That Works Tomorrow, Too
Compressed air systems rarely stay static. Facilities grow, processes change, and demand increases. Designing with growth in mind ensures your system keeps pace without sacrificing efficiency or reliability.
If your facility is planning to expand—or simply wants to avoid future limitations—now is the right time to evaluate whether your compressed air system is ready for what’s next.
We would love to help with your compressed air needs!
📞 901-327-1327
📧 parts@gordonaircompressor.com
📧 service@gordonaircompressor.com
📍 706 Scott Street, Memphis, Tennessee 38112
Emergency Service Available @ 901-482-5925
