With Unipipe, adding a new drop for your compressed air system is fast and simple, whether you are using our pre-assembled drop end assemblies or a traditional manifold assembly. Let’s explore the options and see how they work.

Tying the Drop into the Loop: Tee vs. Saddle Connection

When connecting drops to a compressed air or multi-fluid system, the method you choose can significantly impact installation time, flexibility, and downtime. Traditional piping systems use a Tee connection to tie the drop into the main distribution loop. Unipipe’s saddle connector makes the process significantly faster and easier, with no special tools, threading, crimping, grooving or hot work required. Here’s the difference.

How a Traditional Tee Connection Works

A Tee connection involves cutting into the main loop or header pipe to install a T-shaped fitting that branches off to a drop line. Here’s how the process typically unfolds:

Position determination: The exact position for the Tee must be planned during the initial construction of the piping system or determined later if adding new drops.
Pipe cutting: The header pipe is cut at the chosen point, interrupting the system and requiring downtime.
Fitting installation: The Tee fitting is inserted between the two cut ends of the pipe and secured using threading, welding, or other attachment methods.
Reconnection and testing: After securing the Tee, the pipe is reconnected, sealed, and tested to ensure it is leak-free.
Drop line installation: The drop line is attached to the Tee’s side port, completing the connection.

A traditional Tee connection installation has significant downsides:

Requires downtime: Cutting into the header pipe disrupts operations and takes the system offline.
Rigid planning: The position of the Tee must be finalized early in the construction process. Changes or adjustments later are time-consuming and costly.
Labor-intensive: Cutting, sealing, and reconnecting the pipe requires skilled labor, precise alignment, and significant time. Depending on the type of piping material, installing the connection may require grooving, crimping, threading, and/or hot work.
Risk of leaks: Multiple connection points increase the potential for leaks if not assembled perfectly.

How the Unipipe Saddle Branch Connector Works

The saddle eliminates the need to cut into the header pipe, offering a simpler and more flexible solution. Here’s how it works.

Remove the bolt and slide the clamp half to one side until it is free. Check to make sure the seal is in place in the saddle branch body.
Place the saddle branch body on the pipe in its approximate position and slide the clamp half into the body. Check the final position and then insert the bolt and tighten.
Drill a hole in the pipe using a hole saw matched for clearance fit in the diameter of the inner hole. Carefully deburr edges of hole and remove all metal shavings.

The Unipipe saddle branch connector offers several key advantages.

No pipe cutting: Installation doesn’t require cutting into the header pipe, preserving its integrity and reducing complexity.
Minimal downtime: The system can remain operational while the saddle is installed, saving time and money using the ‘hot-tap’ process.
Flexible placement: Drops can be added after machinery is installed or as needs change.
Reduced labor costs: The saddle’s clamp-on design simplifies installation, requiring no specialized tools or skilled labor.
Leak-free reliability: High-quality gaskets ensure an airtight seal, reducing the risk of leaks compared to manually assembled Tee fittings.

Choosing a Drop Style: Manifold vs. Pre-Assembled Drop-End

When deciding how to configure your drop, Unipipe offers two versatile options: a traditional manifold assembly or a pre-assembled drop-end. Each style has its own strengths, depending on your specific application needs.

Traditional Manifold Assembly

Manifolds are a tried-and-true option for compressed air systems, providing a central hub for multiple connections. They are best for applications where multiple hoses, tools, or equipment need to share a single drop. A traditional manifold assembly offers:

Customizable configurations: Manifolds allow you to attach multiple quick-connect fittings or hose connections.
Centralized control: Manage multiple connections from a single location.

Manifold assemblies require on-site assembly, adding time and labor to the installation process. Precision is key to ensuring a leak-free setup. However, in the Unipipe system, a manifold can be added to one of our drop-ends for simplified installation using our saddle branch connectors.

Pre-Assembled Drop-End Assemblies

Unipipe’s pre-assembled drop-end assemblies take the guesswork and labor out of the equation, offering a fast, plug-and-play solution. They offer simple, single-point connections or situations where installation speed and ease are priorities.

Ready to install: Each drop comes fully assembled with airtight connections, reducing the need for skilled labor.
Integrated components: Includes a ball valve, drip leg, mounting hardware for simple wall or Unistrut installation, and a single or double port with optional quick-disconnect fittings.
Time-saving: No on-site assembly means significantly faster installation compared to traditional manifolds.

Unipipe’s drop-end assemblies come in single or double port options and a variety of drop-end styles, including:

Threaded ball valve drops: Ideal for direct connections to stationary equipment, offering precise control and secure operation.
Quick-disconnect fitting drops: Perfect for mobile or portable tools, these drops make tool changes fast and hassle-free.
NPT adapter hose reel drops: Designed for overhead or workspace-level applications, providing clean, organized access to air supply.

Which Drop Style Is Right for You?

Your choice depends on the specific needs of your system.

Use a manifold assembly if you need to connect multiple tools or hoses from a single drop and value centralized control.
Choose a pre-assembled drop-end if speed, simplicity, and a clean, professional installation are your top priorities.

Ready to Learn More?

Unipipe makes installing drops for your compressed air system faster, easier, and more efficient than ever. Whether you need the flexibility of a manifold assembly or the speed and simplicity of a pre-assembled drop end, Unipipe has a solution tailored to your needs. With innovative saddle connectors and versatile drop styles, you can create a system that adapts to your operations with minimal downtime and maximum reliability.