Master controller: SIGMA AIR MANAGER 4.0

Key technology for Industrie 4.0

The next generation of compressed air management master system, the SIGMA AIR MANAGER 4.0 utilises adaptive 3-Dadvanced Control to make air generation and treatment even more intelligent, reliable and efficient.

  • The 3-Dadvanced Control analyses all operating data on an ongoing basis, simulates alternative actions and calculates the perfect compressor combination. The result: Unprecedented energy efficiency.
  • Maintain an overview at all times thanks to easy operation, visualisation and analysis. With secure network technology – conveniently from any PC.
  • Predictive Maintenance by Kaeser specialists prevents unplanned downtime.

And if you have big plans for the future: The SIGMA AIR MANAGER 4.0 is designed to grow with your air station. A simple software upgrade allows expansion of the master controller without the need for additional investment in new hardware.

Your advantages

  • Smart:
    The SIGMA AIR MANAGER 4.0 not only registers switching losses, but all factors that affect your compressed air station. It then uses the gathered information to calculate the achievable optimum performance values and controls all connected components accordingly.
  • Secure:
    Together the SIGMA AIR MANAGER 4.0 and the powerful Ethernet KAESER SIGMA NETWORK form a future-dynamic infrastructure that meets all requirements for a highly-secure industrial control system.
  • Efficient:
    Continuous fine adjustment with a view to achieving optimum energy efficiency (energy management in accordance with ISO 50001) and the option of predictive, demand-oriented maintenance keep life cycle costs to an absolute minimum.

Our SIGMA AIR MANAGER  4.0 master controller in detail

Optimisation process

The SIGMA AIR MANAGER 4.0 calculates future demand based on past compressed air consumption profiles. On the basis of this demand projection, the technical conditions of the components and the learned knowledge regarding the system and its behaviour, the patented simulation-based optimisation process is used to anticipate the most efficient switching operations.


Industrial applications place special demands on communications technology, particularly in the field of machine-to-machine communication. It must be robust and locally manageable, as well as globally-compatible and also capable of transferring large data volumes quickly and securely. The system must also ensure maximum data integrity and provide the necessary real-time properties required by the process. The KAESER SIGMA NETWORK meets all these requirements and more.

Together with the SIGMA AIR MANAGER 4.0 compressed air management system, the KAESER SIGMA NETWORK creates a perfectly matched secure infrastructure for intelligent services within the advanced scope of Industrie 4.0 operating environments. If required, operating data from the compressed air station can be securely transmitted to the KAESER DATA CENTER via a broadband connection.

The combination of remote diagnostics and demand-oriented predictive maintenance ensures maximum compressed air supply availability and complete system effectiveness.

  • Prevention of unplanned and planned downtime (malfunctions / maintenance) through evaluation of operating parameters, such as load operating hours and temperatures
  • Increased energy efficiency through monitoring of key operating parameters such as airend discharge temperature, pressure dew point, differential pressures (filters), leakage rates, pressure and flow rate
  • Service costs reduced by up to 30% through optimised servicing and avoided repairs
  • Demand-optimised compressed air system control throughout the system's entire life-cycle
KAESER SIGMA NETWORK offers connection to a desktop, laptop or tablet and to your own control centre.