Intelligent Air Injection System
An engineered solution combining a custom-built ROTOMAC Progressive Cavity Pump with compressed air conveying — delivering low pipeline pressure, 60% energy savings, distances up to 1,000 metres, and full automation control via the SAI controller.
Energy60% Less Than Alternatives
SavingsReduced Pipeline Wear & Costs
RangeUp to 1,000 Metres Distance
ControlSAI Controller — Full Automation
Result60% Less Energy. Longer Pipe Life. No Limits on Distance.
PC Pump + Compressed Air — One Engineered System
The Intelligent Air Injection System (IAIS) is an engineered conveying solution that combines a custom-built ROTOMAC Progressive Cavity Pump with compressed air to move viscous or semi-solid products through long pipelines — safely, efficiently, and with minimal energy.
Unlike conventional pneumatic conveying or single-pump systems, the IAIS maintains a deliberately low pressure level throughout the conveying pipeline. This has two major consequences: dramatically reduced energy consumption and significantly longer service life for the pipeline and connected equipment.
What makes it "intelligent"? The SAI controller monitors all system functions in real time, automatically adjusting air injection timing and volume to maintain optimal low-pressure conditions — regardless of product viscosity, pipeline length, or direction changes. This intelligence is what separates the IAIS from conventional conveying options.
Five Stages of Intelligent Conveying
The IAIS combines positive displacement pumping with precision air injection to achieve long-distance, low-energy product transfer.
PC Pump Meters Product
The custom PC pump draws product from the source and meters it in precise, controlled plugs into the conveying pipeline.
Air Injected Between Plugs
Compressed air is injected between product plugs. The SAI controller manages timing and volume to maintain low, consistent pipeline pressure.
Low-Pressure Transport
Product travels through the pipeline at moderate speed and low pressure — dramatically reducing wear on pipework, bends, and downstream equipment.
Height & Direction Changes
The system flexibly overcomes changes in pipeline direction and height differences — with no additional pumping stages or boosters needed.
Product Arrives Intact
The product arrives at the destination up to 1,000 metres away with its structure, viscosity, and quality fully preserved.
Four Reasons the IAIS Outperforms Conventional Conveying
Every feature of the IAIS delivers a measurable operational benefit — from your energy bill to your maintenance schedule.
Energy-Saving Operation
The low pipeline pressure maintained by the IAIS means the system works far more efficiently than conventional pneumatic conveyors or high-pressure pump systems. Total energy consumption is significantly lower — making the IAIS a cost-effective long-term investment for high-throughput operations.
vs. other conveying options
Improved Service Life
Because the product moves through the pipeline at moderate speed under low pressure, pipework wear and tear is dramatically reduced. Bends, T-pieces, and straight sections last significantly longer — lowering the cost and frequency of pipe replacement and unplanned maintenance shutdowns.
Saves repair & replacement costs
For Long Distances & Height Differences
The IAIS effortlessly handles long transfer distances and changes in direction or elevation that would be impractical or impossible with conventional pump-only arrangements. Single pipeline routes can span entire factory floors, cross buildings, or move product to elevated storage tanks.
with flexible routing
Easy to Control & Integrate
The SAI controller monitors and manages all system functions from a single interface — displaying pipeline status, air injection cycles, flow rates, and alarms in real time. The system integrates cleanly into existing plant automation and control architectures via standard communication protocols.
Integrates with any automation system
Why IAIS Over Other Options?
Conventional high-pressure pneumatic conveying, centrifugal pump systems, and screw conveyor arrangements all have well-known limitations in long-distance, viscous-product applications. The IAIS was engineered specifically to overcome them.
Typical Applications
The IAIS is ideal wherever viscous, semi-solid, or high-value products need to be transferred over long distances, across floors or buildings, or through complex pipeline routes — without high pressure or high energy costs.
Food & Beverage
Transfer of jams, pastes, sauces, dairy products, honey, and viscous food intermediates from production to filling lines or storage tanks across long factory distances.
Chemical & Polymer
Long-distance transfer of resins, adhesives, polymer slurries, and chemical intermediates through enclosed pipeline systems — with no product exposure and precise flow control.
Cosmetics & Personal Care
Hygienic pipeline transfer of creams, lotions, gels, and high-viscosity cosmetic formulations from mixing vessels to filling stations or storage — preserving product quality throughout.
Pharmaceutical
Transfer of pharmaceutical pastes, ointments, gel formulations, and excipient slurries through cleanable, enclosed pipeline systems — with full process monitoring via the SAI controller.
Printing & Coatings
Long-distance transfer of inks, varnishes, coatings, and pigment pastes from storage to printing and coating lines — with accurate, metered dosing via the PC pump.
Environmental & Wastewater
Transfer of sludges, digested biomass, and conditioning chemicals over long distances within treatment plants — where high-pressure conveying would cause excessive wear and cost.
The Brain of the System SAI Intelligent Controller
The SAI controller is what makes the IAIS truly intelligent. It monitors and manages all system functions automatically — constantly optimising air injection timing, volume, and frequency to maintain low pipeline pressure and maximum energy efficiency, regardless of product load or pipeline conditions.
Interested in the IAIS for Your Plant?
Tell us your product type, transfer distance, flow rate requirement, and layout — our engineers will design the right IAIS configuration for your application.
Head Office
D-4a, Panki Industrial Area, Site-1,
Kanpur – 208022, Uttar Pradesh, India