When a major logistics operator built a new fully automated distribution hub in Sydney, they needed more than just compressed air — they needed a system that was powerful, efficient, and future-ready.
Air Energy partnered with the client from day one, working closely with their engineers to design and deliver a high-efficiency compressed air system that could handle today’s workload and scale for tomorrow.
The Brief: Reliability Meets Efficiency
The client’s requirements were clear:
- A system that’s reliable under pressure
- Energy-efficient under load
- Easy to maintain
- Safe to install in a busy construction environment with sensitive equipment and multiple trades on site
The Setup: A System Built to Perform
We supplied and installed a matched pair of Atlas Copco GA55VSDFF & GA55FF compressors, feeding into a 2,900L air receiver (so big it barely fit through the exit door).
From there, air runs through a custom-designed 108mm 304 stainless steel mainline, branching into multiple smaller-diameter stainless lines that supply over 150 outlets across the warehouse floor.
To ensure consistent flow and balanced pressure, we designed a figure-8 ringmain layout, a proven method for large-scale distribution centres.
Why Stainless Steel Press Fittings?
For a project of this scale, choosing press fit stainless steel pipework over welded systems delivered big advantages:
- Faster installation: up to 10x quicker than welding
- Lower labour costs: no certified TIG welder required
- Improved safety: no flames, no fire hazard
- Less disruption: compact tools, minimal setup, perfect for tight or live environments
- Future flexibility: modifications and expansions made simple
Compared to traditional welding or other stainless press systems, this approach cut installation costs by up to 30% while delivering long-term reliability.
Coordinating With Other Trades
This wasn’t a standalone job. The site was a hive of activity, with electrical, mechanical, racking, and robotics teams all working to a tight construction schedule.
Air Energy coordinated closely with other trades, ensuring our compressed air system installation was seamless, on time, and aligned with the broader project.
The Outcome: A Future-Ready Distribution Hub
The result is one of Sydney’s largest distribution centres powered by a robust, efficient, and scalable compressed air system, designed to keep pace with automation and high-volume stock movement.
Ready to Build Your Next Facility?
Whether you’re building a new distribution hub or upgrading a compressed air system that’s no longer keeping up, Air Energy delivers solutions that work, safely, efficiently, and without the usual headaches.
Talk to our engineers about designing a system for your site.