When a leading logistics company built a fully automated distribution hub in Sydney, they needed more than just compressed air. They wanted a system that was powerful, efficient, and ready for the future.
Air Energy worked with the client from the start, teaming up with their engineers to design and deliver a high-efficiency compressed air system that meets current needs and can grow with future demands.
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 and GA55FF compressors, which feed into a 2,900L air receiver. The receiver was so large it almost didn’t fit through the exit door.
From there, the air moves through a custom 108mm 304 stainless steel mainline, which branches into smaller stainless lines supplying more than 150 outlets across the warehouse floor.
To keep the flow steady and the pressure balanced, we used a figure-8 ringmain layout. This method is proven for large distribution centres.
Why Stainless Steel Press Fittings?
For a project this size, using press-fit stainless steel pipework instead of welded systems brought major benefits:
• 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
This approach can reduce installation costs by up to 30% compared to traditional welding or other stainless press systems, while still providing long-term reliability.
Coordinating With Other Trades
This project was not done in isolation. The site was busy, with electrical, mechanical, racking, and robotics teams all working on a tight schedule.
Air Energy worked closely with other teams to make sure our compressed air system was installed smoothly, on time, and in line with the rest of the project.
The Outcome: A Future-Ready Distribution Hub
The result is one of Sydney’s largest distribution centres, powered by a strong, efficient, and scalable compressed air system. It is built to keep up with automation and high-volume stock movement.
Ready to Build Your Next Facility?
If you are building a new distribution hub or need to upgrade an old compressed air system, Air Energy provides safe, efficient solutions that work without the usual hassles.
Speak with our engineers about designing a system for your site. Contact our team today.