A pneumatic tube system is a network of tubes, fittings and control devices that uses compressed air to power tools, actuators, cylinders and automated processes inside a factory. While compressors and valves often receive the most attention during system design, the tubing that connects everything together has an outsized impact on efficiency, reliability and maintenance costs. Choose the wrong tube material, diameter or wall thickness and even the best compressor will struggle to deliver consistent performance at the point of use.
In this article, we walk through the core concepts behind a factory pneumatic tube system: what it actually consists of, which components make it work, which tube materials suit different operating conditions, and how to size tubing correctly to minimise pressure losses. We also cover practical installation and maintenance considerations that keep systems running reliably over time.
What Counts as a Pneumatic Tube System in a Factory?
A pneumatic tube system in a factory is the complete infrastructure that generates, conditions, distributes and controls compressed air to perform mechanical work. It begins at the compressor and ends at the actuator, cylinder or tool that converts air pressure into motion or force. Everything between those two points, including the tubing, valves, regulators, filters and fittings, forms part of the system.
It helps to think of a pneumatic tubing system as analogous to a building’s plumbing. The compressor is the water pump, the main distribution lines are the supply pipes, and the individual workstation connections are the taps. Just as undersized plumbing causes weak water pressure at the farthest tap, undersized or poorly routed pneumatic tubing causes pressure drops at the farthest machine. If you want a deeper introduction, our guide on what a pneumatic tube is covers the fundamentals in more detail.
Factory pneumatic tube systems range from simple setups with a single compressor feeding a few air tools, to complex multi-zone networks distributing compressed air across an entire production facility. Regardless of scale, the same principles govern performance: clean, dry air must reach each point of use at the correct pressure and flow rate, with minimal energy wasted along the way.
What Are the Main Components of a Pneumatic System?
Every pneumatic system shares a set of core components. Understanding each one helps you see why tubing selection matters so much: the tubes are the connective tissue that links every other component together, and their properties directly affect how well the whole system performs.
- Compressor: Generates compressed air by drawing in ambient air and increasing its pressure. Compressor type and capacity determine the maximum pressure and volume available to the system.
- Air treatment unit (FRL): A combination of filter, regulator and lubricator that conditions the air before it enters the distribution network. Filters remove moisture and particulates, regulators set the downstream pressure, and lubricators add a fine oil mist when required by the end equipment.
- Distribution tubing and piping: The network of tubes, pipes and headers that carries compressed air from the treatment unit to each point of use. This is where material choice, diameter and routing have the greatest impact on system efficiency.
- Fittings and connectors: Push-in fittings, compression fittings, manifolds and quick-disconnect couplings that join tube sections, branch lines and connect to equipment. Every fitting is a potential leak point, so quality and correct installation matter.
- Control valves: Directional control valves, flow control valves and pressure relief valves that manage when, where and how much air reaches each actuator or tool.
- Actuators and end devices: Cylinders, rotary actuators, grippers, air tools and blow-off nozzles that convert compressed air into useful work.
Of these pneumatic system components, the tubing network is often the most extensive in physical terms. A medium-sized factory can easily have hundreds of metres of compressed air tubing running through ceilings, along walls and down to individual machines. That makes the tube material and sizing decisions critical, because even a small inefficiency per metre adds up across the entire installation.
Which Tube Materials Are Used in Pneumatics?
Pneumatic tube materials vary widely in their mechanical properties, chemical resistance, flexibility and temperature tolerance. Selecting the right material means matching these properties to the specific demands of your application, including operating pressure, ambient temperature, exposure to chemicals or UV light, and how much flexibility the routing requires.
Polyamide (Nylon) Tubes
Polyamide tubes, particularly PA11 and PA12 grades, are among the most widely used pneumatic tube materials in industrial settings. They offer a strong combination of pressure resistance, mechanical toughness and chemical compatibility. PA11 is derived from renewable castor oil and tends to offer slightly better impact resistance at low temperatures, while PA12 provides excellent dimensional stability and resistance to stress cracking.
Polyamide tubes are available in hard, semi-hard and soft grades. Hard grades suit fixed distribution runs where rigidity and pressure capacity are priorities. Softer grades offer greater flexibility for connections to moving equipment or robotic arms, where the tube needs to bend repeatedly without fatiguing.
Polyethylene (PE) Tubes
Polyethylene tubes come in several variants, each suited to different pneumatic applications. HDPE (high-density polyethylene) offers good rigidity and pressure resistance for main distribution lines. LDPE and LLDPE are softer and more flexible, making them practical for lower-pressure branch lines and connections. For a detailed comparison of these variants, see our article on polyethylene tubes for pneumatics.
Polyurethane (PUR and TPU) Tubes
Polyurethane tubes stand out for their exceptional flexibility, abrasion resistance and kink resistance. They are a common choice for the final connection between a fixed distribution point and a moving tool or actuator. PUR tubes handle repeated bending cycles well, which makes them popular in robotic applications and on assembly lines where tubes are constantly in motion.
PEX (Cross-linked Polyethylene) Tubes
PEX tubing offers enhanced temperature resistance and mechanical strength compared to standard polyethylene, thanks to its cross-linked molecular structure. It performs well in environments where tubes are exposed to higher temperatures or need to maintain their shape under sustained pressure.
Beyond material type, colour coding of pneumatic tubes plays a practical role in factory systems. Assigning specific colours to different air circuits, pressure levels or functions makes the system easier to trace, troubleshoot and maintain. Colour coding is particularly valuable in complex multi-zone installations where dozens of tubes may run in parallel.
How Do You Size Tubing and Avoid Pressure Losses?
Correct tube sizing is one of the most impactful decisions in pneumatic system design. An undersized tube restricts airflow and creates pressure drops that force the compressor to work harder, wasting energy. An oversized tube increases material costs and stores a larger volume of compressed air, which can slow response times in control applications.
Key Factors in Tube Sizing
Three variables drive tube sizing decisions: the required flow rate at the point of use, the allowable pressure drop between the compressor and the end device, and the total length of the tube run including equivalent lengths added by fittings and bends. As a general principle, longer runs and higher flow rates require larger internal diameters to keep pressure losses within acceptable limits.
Wall thickness is the other half of the sizing equation. A tube’s pressure rating depends on both its material and its wall thickness relative to its outer diameter. Thicker walls handle higher pressures but reduce the internal bore, so there is always a balance to strike. Our guide on wall thickness and pressure rating explains how to evaluate this relationship for different materials and operating conditions.
Common Sources of Pressure Loss
Pressure losses in a pneumatic tubing system come from several sources, and most of them are controllable through good design:
- Friction along the tube wall: The longer the tube run and the smaller the bore, the greater the friction loss. Smooth internal surfaces reduce friction compared to rough ones.
- Fittings and connectors: Every elbow, tee, reducer and coupling adds resistance. Minimising the number of fittings and using sweep bends instead of sharp elbows reduces cumulative losses.
- Leaks: Even small leaks at fittings, joints or damaged tube sections waste compressed air continuously. Industry experience suggests that leaks are one of the largest sources of energy waste in factory compressed air systems.
- Contamination: Moisture, oil and particulates inside the tubing increase friction and can partially block small-bore tubes or fittings over time.
A practical approach is to design the system with the shortest practical tube runs, use the fewest fittings possible, and select tube diameters that keep flow velocity within a moderate range. Excessively high flow velocities generate turbulence and noise, while very low velocities may indicate an oversized and unnecessarily expensive installation.
What Should Be Considered in Installation and Maintenance?
Even the best-specified tubing will underperform if installed carelessly or neglected after commissioning. Building on the sizing and material principles covered above, good installation practices protect the system’s efficiency over its full service life.
Installation Best Practices
Route main distribution lines with a slight slope to allow condensate to drain toward collection points rather than pooling inside the tubing. Support tubes at regular intervals with appropriate clips or clamps to prevent sagging, which creates low spots where moisture accumulates. When routing tubes near heat sources, verify that the selected material can handle the ambient temperature without softening or deforming.
Avoid sharp bends that exceed the tube’s minimum bend radius. Bending a tube too tightly restricts the internal bore, creates a localised pressure drop and can weaken the tube wall over time. If tight routing is unavoidable, use elbow fittings or pre-bent tube sections designed for the purpose.
Ongoing Maintenance
Regular leak detection is the single most valuable maintenance activity for a compressed air tubing network. Walk the system periodically and check every fitting, joint and connection point. Ultrasonic leak detectors can identify leaks that are not audible in a noisy factory environment.
Inspect tubes for signs of wear, discolouration, cracking or swelling, particularly in sections exposed to heat, UV light, chemicals or mechanical abrasion. Replace damaged sections promptly rather than applying temporary repairs. Drain moisture traps and check filter elements on a regular schedule to keep the air supply clean and dry, which in turn protects the tubing and downstream components.
Toppi Manufactures Tubing for Pneumatic Systems
At Toppi, we have manufactured extruded plastic tubes at our Espoo facility since 1953, and pneumatic tubing is one of our core product areas. We produce tubes from high-grade technical materials including PA12, PA11, HDPE, LDPE, LLDPE, PEX, PUR and TPU, each selected for the specific demands of compressed air and pneumatic applications. Our ToppTube™ range covers hard, semi-hard and soft grades of polyamide, multiple polyethylene variants, and flexible polyurethane options.
We also manufacture multi-tube cables, spiral tubes and pre-bent tubes using CNC bending equipment, which allows us to deliver tubing ready for direct installation in complex pneumatic systems. With over 70 years of extrusion expertise and our own in-house tool shop, we can produce custom tube dimensions, material combinations and co-extruded multi-layer constructions tailored to your specific operating conditions.
Browse our tube range to see the full selection, or tell us about your pneumatic tubing requirements and we will recommend the most suitable product. Contact our team to request a quote or discuss your project.
