Increase your inlet air with the help of boosters

Pressure Boosters: Application, Design, and Selection Criteria for Industrial Applications

Pressure boosters increase existing pressure without additional compressors and are useful in manufacturing, assembly, and automation where local pressure peaks, long pipe runs, or energy-efficient solutions are required. They typically consist of an inlet and outlet chamber design, a boosting mechanism, and sealing systems that vary depending on the medium and environment. Key selection criteria include the medium (compressed air, hydraulic oil), the input pressure range, the desired output pressure, flow requirements, and installation conditions.

Typical Designs and Materials

Pressure boosters are available as inline modules, block housings, or integrated modular components. Housing materials range from die-cast aluminum to hardened stainless steels and corrosion-resistant plastics for corrosive environments. Internal moving parts such as pistons, diaphragms, or valve bodies are usually made of high-strength steel or brass, while guides and seating surfaces are often hardened or coated to minimize wear. Seals come in NBR, FKM (Viton), EPDM, or PTFE versions, depending on temperature, pressure, and medium requirements. For food or pharmaceutical applications, only FDA and USP-compliant materials are used.

Connection Types and Integration Options

Mechanical connections are standardly designed as threaded connections (G, NPT), quick connectors, or flange connections. For electrical control, variants with integrated sensors, pressure switches, or external measuring points that can be connected via 4–20 mA or IO-Link are available. Mounting surfaces are usually machined according to ISO standards to facilitate block mounting in plant frames. For retrofit projects, the variant with defined mounting holes and flexible connection nozzles is recommended to minimize adaptations to existing pipe layouts.

Sealing Systems and Medium Compatibility

The selection of the seal depends on the temperature range, type of medium, and cycle frequency. NBR is suitable for general compressed air applications up to approximately +80 °C. FKM offers resistance to oils and high temperatures up to approx. +200 °C. EPDM is used for steam and hot water, while PTFE is employed for chemically aggressive or very high-temperature conditions. The combination of seals with suitable lubricants extends service life and reduces leakage, although the compatibility between lubricant and sealing material must be checked.

Operating Principle and Control Strategies

Pressure boosters operate on the principle of force transmission: a higher output pressure is generated from a lower input pressure through different piston areas or mechanical transmission. There are stepless, stepped, and blocking systems. Stepless boosters allow continuous regulation, while stepped devices provide defined pressure levels. For precise processes, pressure monitoring sensors are integrated into the output and coupled into control loops to actively compensate for pressure fluctuations during load changes.

Selection Criteria and Design Parameters

The following parameters are crucial for correct dimensioning: available input pressure range, desired output pressure including safety margin, required volumetric flow at maximum demand, permissible pressure losses in pipes, ambient temperature, cycle frequency, and maintenance intervals. Noise levels, energy efficiency, and service life are also economically relevant. Special requirements such as explosion-proof design (ATEX), food-grade material, or cleanroom compatibility influence material selection and surface treatment.

Practical Examples

Practical Example 1: In a press system for sheet metal forming, a pressure booster is installed between the central compressed air supply and the ram cylinder to deliver peaks of 16 bar during short work strokes, while the system operates at 6 bar in idle. The boosting is achieved via a double-acting piston principle with FKM seals for oil mist resistance. An integrated pressure sensor monitors the output pressure and sends pulses to the PLC for cycle monitoring.

Practical Example 2: In a production line for plastic parts, an inline pressure booster compensates for pressure losses over long pipe runs. Designed for a maximum flow rate of 500 l/min and an output pressure of 10 bar, a reinforced aluminum block housing with PTFE-coated pistons is used to reduce friction and ensure fast switching cycles. The connections are designed as quick couplings to allow module changes in a few minutes.

Practical Example 3: In a paint booth, a pressure booster is used to ensure constant atomization pressures. Due to aggressive solvents and elevated temperatures, stainless steel housings and FKM seals are employed. The integration of a pressure regulator with feedback to the process control system allows automatic calibration during color changes.

Installation, Commissioning, and Maintenance

Installation begins with checking the inlet pressure and pipe diameters; undersized supply lines cause pressure losses that reduce the boosting effect. Before commissioning, filters and condensate drains must be checked, as moisture and particles shorten seal service life. For electrical connection, ensure correct grounding and EMC-compliant routing of sensor cables. Maintenance intervals depend on operating hours and cycle frequency; common measures include seal replacement, inspection of seating surfaces, and cleaning of filter elements. For critical applications, a documented inspection and replacement interval with spare parts inventory is recommended.

Safety and Normative Requirements

Depending on the application, pressure boosters are subject to the Pressure Equipment Directive, Machinery Directive, and, if applicable, ATEX regulations. Safety valves, rupture discs, or pressure-limiting devices must be provided if dangerous conditions can arise from a failure of the control loop. Switching and control components in hazardous areas must be appropriately marked and certified.

Lifecycle, Costs, and Economic Efficiency

The economic efficiency of a pressure booster results from lower investment costs compared to additional compressors, reduced energy consumption with demand-oriented operation, and lower piping network requirements. Lifecycle costs include acquisition, installation, maintenance, seal and wear part replacement, and unplanned downtime. Careful design reduces failure risks and lowers total operating costs.

Further Information and Application Examples

For technical data sheets, material combinations, and detailed application cases, please visit our technology page at https://maku-industrie.de/technik. Practical application reports and project-related application examples can be found at https://maku-industrie.de/anwendungsbeispiele. When planning complex systems, early involvement of the responsible maintenance department is recommended to define replacement intervals and spare parts strategies.

Selection Checklist (compact)

• Medium, input pressure, target output pressure, volumetric flow, connection type, temperature range, sealing material, maintenance strategy

Frequently Asked Questions (FAQ)

1. When is a pressure booster a better solution than an additional compressor?

A pressure booster is advantageous when only local pressure peaks are required or for long pipe runs, because it incurs significantly lower investment and installation costs, requires less space, and operates more efficiently under intermittent load than an additional compressor.

2. Which seal should I choose if my system has oil mist and high cycle counts?

For oil mist exposure and high cycle frequency, FKM seals with suitable lubrication and hardened seating surfaces are recommended; PTFE-based seals additionally offer low friction but must be checked for temperature and chemical resistance.

3. How does pipe length affect the dimensioning of a pressure booster?

Long pipes increase pressure losses and delay times, so diameters and surface roughness must be designed such that the required volumetric flow arrives at the point of use without significant pressure drop; in many cases, the booster should be placed closer to the consumer.