Cut Costs, Boost Efficiency: Five Tips To Transform Your Operations

Choosing the best motion control technology is a critical step in refining your manufacturing operation. For example, the decision between pneumatic automation and electric motion control carries significant weight and can directly influence efficiency, costs and overall performance.

Here are five tips to guide you in optimizing your operations through smart motion control choices.

1. Consider the Total Cost of Ownership

While upfront costs are important, think about the total cost of ownership (TCO). Pneumatic automation usually has a lower initial cost than electric motion control. However, ongoing energy expenses, equipment maintenance and lifespan are also key. Pneumatics are cheaper for high-force needs, while electric actuators can save money over time through better energy efficiency.

2. See Where You Can Cut Energy Costs

Because energy costs can add up quickly, it’s important to choose the most efficient system. Pneumatic systems, which rely on compressed air, can experience leaks and other inefficiencies that drive costs. Implementing smart air preparation — like high-quality filtration and pressure control — is crucial to mitigate these losses. On the other hand, electric motion control systems, which turn electrical energy into motion, often provide better energy efficiency for continuous tasks.

3. Consider Balance, Precision and Speed

Ask yourself which motion control technology can best fit your needs. Pneumatic actuators respond quickly, making them great for high-speed operations, while electric systems deliver high precision and flexibility, making them well-suited for tasks that need exact positioning and reliable repeatability.

4. Understand Your Maintenance Bandwidth

Pneumatic systems generally have fewer moving parts, leading to lower maintenance needs. However, they do require regular checks for leaks and proper lubrication in order to continue performing reliably. Electric motion control systems, on the other hand, can be hard to troubleshoot yet typically need less maintenance overall. For both technologies, predictive maintenance strategies can go a long way toward reducing downtime.

5. Consider Hybrid Solutions

Sometimes, the best option isn’t a simple choice. Hybrid systems that blend pneumatic and electric components provide advantages from both types. For instance, use pneumatics for high-speed tasks and electric actuators for precise movements — an approach that maximizes efficiency while controlling costs.

The Bottom Line

Both pneumatic automation and electric motion control have their strengths, and oftentimes the right choice depends on your specific needs. Need help selecting the right motion control solution? Contact our experts at Festo today.