Real-time Compressed Air Quality Monitoring for ZEISS
Identifying air quality deviations during commissioning
Application
Compressed air quality monitoring for production qualification in high-precision optical manufacturing.
Goal
Verify compressed air quality, identify the source of particle contamination and support successful project acceptance.
Customer
ZEISS, China
Sector
High-precision optical manufacturing
Overview and Challenge
1. Overview
ZEISS, a global leader in high-end optical manufacturing, built a new compressed air station in China to supply production workshops with reliable and clean compressed air. Because compressed air quality has a direct impact on production reliability and product quality, the new system had to be qualified before project acceptance.
2. Challenge of the Customer
During commissioning, particle levels in the compressed air exceeded the acceptable limits. This created a risk of delayed project acceptance and potential production delays. As the site operated four identical compressed air systems, visual inspection alone was not enough to identify which system caused the deviation. A clear measurement-based approach was needed to locate the source of contamination quickly and avoid unnecessary rework.
Solution and Implementation
3. Solution and Implementation
The SUTO iTEC team used the S600 Portable Compressed Air Quality Analyzer to test all four compressed air systems under comparable conditions. The measurements covered particles, dew point and oil vapor to provide a complete overview of compressed air purity. The data showed that one system had significantly higher particle levels than the others. A follow-up inspection identified a faulty filter, which was replaced to restore compressed air quality compliance.
Results and Conclusion
4. Results
The measurements enabled a fast and accurate identification of the faulty system. ZEISS was able to avoid unnecessary troubleshooting across all systems, reduce rework and move forward with project acceptance based on clear measurement data.
Four Systems Verified
Compressed air quality was verified across all four parallel systems.
Compliance Restored
100% compliance was restored after the faulty filter was identified and corrected.
Faulty Filter Identified
Targeted fault detection avoided unnecessary rework and reduced time and cost during commissioning.
Project Acceptance Supported
The project improved confidence in daily compressed air quality monitoring and long-term quality management.
Follow-up Engagement and Customer Visit
After the successful commissioning support, SUTO iTEC CEO Jan Vansweevelt and the local distributor visited ZEISS for an on-site tour and follow-up meeting. Based on the positive experience, the customer added further SUTO iTEC solutions for daily operation monitoring and compressed air quality management.
5. Conclusion
By using professional compressed air quality measurement and data analysis, SUTO iTEC enabled precise fault detection during commissioning and helped ZEISS restore compliance. The case shows how reliable monitoring supports production qualification, operational confidence and quality assurance in high-precision manufacturing environments.
6. Products in Use
The following SUTO iTEC solutions were used or selected for compressed air quality monitoring and daily operation management at the site.
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