TEM Journal | 2026
Authors: Titova T.; Kosturkov R.
DOI: 10.18421/TEM151-02
Journal: TEM Journal
Year: 2026
Publisher: UIKTEN - Association for Information Communication Technology Education and Science
Document Type: Article
Open Access: All Open Access; Gold Open Access
Cited by: 1
Industrial pneumatic systems consume significant energy in manufacturing, with leakage losses being a major inefficiency. While previous studies highlight the value of systematic leak detection and maintenance, practical decision-making often lacks structure. This study explores minimizing leakage in bottling plants while reducing component replacement costs. The guiding hypothesis is that metaheuristic optimization can generate Pareto-optimal solutions that balance these two conflicting objectives. Leakage audits were performed in 12 Bulgarian bottling facilities, identifying 2,112 major leaks (>5 l/min) using ultrasonic detection. Data from compressors, leakage volumes, and electricity rates were used to assess energy and financial losses. Four component groups—push-in fittings, FRL units, air grippers, and valves—were responsible for over 50% of the total leakage, equating to 76,228 l/min or 503,836 kWh in monthly energy waste. A metaheuristic Pareto-ranking method was applied to prioritize component replacement, balancing cost and efficiency. The findings demonstrate the value of datadriven tools in industrial maintenance, supporting cost reduction, sustainability, and improved competitiveness in pneumatic system management. © 2026 Tanya Titova & Rosen Kosturkov; published by UIKTEN. This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 License.
energy and financial losses; energy efficiency; leakages; metaheuristic method; optimization; Pareto; Pneumatic system