Working in an industrial setting requires a lot of energy to power all the heavy machinery needed to get the job done. One of the best forms of energy to power these tools is compressed air. When it comes to industrial setting, a large, industrial sized air compressor is the way to go to get the most power and efficiency for the most amount of tools at once.

The way a compressed air machine works is by filling up a large tank with air, then compressing it down through smaller chambers and tubes, before finally being pushed out of the system via an attached hose. The problem with compressed air is that there is a lot of moisture and micro particles, such as dust and oils, in the air being compressed. It is important to remove this moisture from your system in order to keep it contaminant free and running at full capacity.

In order to remove this unwanted moisture and liquid condensates in your industrial air compressor, you are going to need an air dryer, a device that is attached to the air compressor or built into the system itself that will keep moisture out of the pneumatic hoses.
There are three basis types of dryers that are used in an industrial air compressor: refrigerated air dryers, desiccant dryers, and dehumidifying membrane dryers. While all three accomplish the same goal of removing moisture from the system, they each go about this in different ways.

The most common type of air dryers today is the refrigerated dryer, which using a cooling method to reduce the temperature of the air, allow the water vapor in the machine to condense into a liquid form, and then have it easily drained away just outside the refrigeration chamber. The compressed air itself loses none of its power when it goes through the refrigerated chambers but the moistures are removed, making this not only a very efficient way of removing moisture, but also a safe and cost effective way.

The oldest type of air dryers are the desiccant dryers, which utilize chambers with desiccants in them to absorb moisture directly from the air without changing its temperature. A desiccant is a small cloth bag containing silica gel which absorbs water at a very fast rate and also retains that water so it does not leak out of the system. The cleansing of this system is a simple matter of going into the desiccant chamber directly and physically removing the desiccants, and then replacing them with fresh ones. This is another highly effective and cost efficient process, just be sure to always take care of the desiccants in the system.

The final type of air dryers is also the newest and uses a dehumidifier membrane at different stages of the compressed air process to remove all the liquid. This multiple step process is designed to filter out moisture and contaminants as they form in the compressed air system, and by running through several different levels of dehumidifiers, you can be assured that the compressed air in your pneumatic hoses will be moisture free.

As with all industrial air compressor parts, preventative maintenance is the golden rule to follow, and choosing the right kind of dryer is up to you and what you want out of your industrial air compressor system. Check out a reputable, established air compressor dealer for more information on dryers.

Condensate filters are not mandatory for the operation of an air compressor. However, discharge of condensate is often regulated by local municipalities. Condensate filters ensure that toxic contaminants are safely separated for easy management of condensate. The combination of oil and water that comprise condensate are difficult to dispose of safely if not filtered. Installing a condensate filter is the environmentally conscious and responsible thing to do.

An air compressor works by using mechanical force to increase air pressure within a contained tank. As the air is compressed, it heats under pressure as it is introduced into the receiving tank. The initial heating will cause any water molecules in the air to vaporize, but the air cooling that occurs in the aftercooler and receiving tank will condense the vapor into a liquid. This is how water gets into the system. In addition to the ambient air moisture that is drawn into a compressor system at the air intake, the compressor's machinery also contributes to the condensate pool.

The moving parts of an air compressor must be lubricated to ensure a long operating life with limited wear. Unfortunately, atomized amounts of the oils and lubricants used in air compressors find their way into the pressurized air of the system. As the air is circulated from the compression cylinder to the receiver and output, the condensate will collect in several low areas of the system because the water and oil molecules are heavier. Blowing the condensate out through a release valve will discharge atomized particles of contaminants that include abrasive solids, compressor lubricants, and condensed water droplets, and these substances can be acidic. Continual discharge of these contaminants can be bad for operators and the environment.

A condensate filter is designed to separate the hazardous chemicals from the safe water for responsible disposal. The way this works is the filtration unit will usually attach to one of the compressor's existing blow-downs. The pressure of the air inside is used to push out water droplets and hazardous chemicals that are trapped inside the system. As the contaminants are introduced into the condensate filtration unit, they pass through a filter that will catch oils and hazardous debris while allowing water droplets to pass through. The end result is a container full of safe water that can be disposed in any drain. The filter is a consumable that must periodically be changed and properly disposed of by following hazardous material handling protocols. Condensate filters are effective in protecting operators while providing safe HAZMAT handling in an inexpensive manner.

Compressed air has many industrial applications. The use of compressor equipment can, however, create its own difficulties. One of the problems that the users of compressed air must deal with is condensation that occurs within the equipment.

When air is compressed, contaminants within the air are concentrated, including water vapor. Condensation occurs when the elements that have been compressed cool as they travel away from the compressor. The end result can be freezing of the air lines, corrosion in the pipes and, ultimately, malfunctioning of the equipment. Additionally, moisture can reduce the effectiveness of lubrication that might be used within the equipment. There are a number of things operators of compressors can do to deal with this nuisance.

To reduce condensation, the operator should always take drops off the top of main line, which will make for easier draining of the system. Main lines should always be pitched toward a drain or tank. Any valve that is used should be installed ahead of the drain, which will also enhance maintenance. The use of "drip legs" can be beneficial in collecting moisture that develops within air pipes, and should always be placed in the low points of an air line. They are also needed in pipes that run from outdoors into an indoor setting because of differences in the atmosphere, with a warmer ambient temperature and a higher relative humidity producing greater levels of condensation.

Stainless steel is the best material for use in compressors that do not rely upon lubrication. Oil can actually reduce corrosion in compressor systems using traditional black iron pipes. However, when oil becomes contaminated with moisture, the substance is considered a hazardous material and requires proper disposal.

A compressed air dryer is a piece of equipment that can be used to reduce condensation.
Additionally, different types of drains are available to eliminate the moisture that appears. The manual drain is the basic type, although other drains are operated by floats or timers and will automatically eliminate condensation. An elaborate drain has an electronic sensor to evaluate the amount of condensation and remove it when needed.

Operators of compressor equipment should never underestimate the possibility of condensation, and take the proper steps needed to reduce the risk.

Compressed air is a great tool to use on any job, from outdoor construction work to indoor factory utility, compressed air can power virtually any tool you need. In order to get enough compressed air for those large, heavy pieces of machinery, you are going to need an industrial size air compressor. When it comes to buying an industrial air compressor for your business, many people would immediately shy away from buying a pre-owned model, but there are a few benefits to purchasing a pre-owned air compressor over a brand new one.

One of the first, and probably most obvious, benefits of buying a pre-owned industrial air compressor over a brand new model is the cost of the unit itself. Brand new models can be quite pricey, and start-up businesses such as machine shops or even auto garages might not have the cash lying around to spring for a shiny new air compressor.

A pre-owned air compressor system will carry the power and reliability of a large, industrial scale model but often at the cost of a smaller, more personal model. Not only does this save your business a good deal of money, but you get the same amount of power as if you sprang for that brand new model.

It is a common misconception that just because a product is labeled “used” or “pre-owned” that it is automatically considered lesser quality. When it comes to industrial air compressor units, this is most certainly not the case. A worn out industrial air compressor will have notcable signs of wear, so these units should be avoided. However, most unites will not only run smoothly and efficiently, but if proper maintenance was taken on the unit, it will run as if it were brand new.

Another selling point to buying a pre-owned air compressor unit is that often times the seller will still have the warranty in place on the unit, adding peace of mind when buying such a big piece of machinery. If, for whatever reason, the unit should break down, the warranty will cover any repair costs, so you do not have to worry about sinking a lot of money into a pre-owned machine.

An industrial sized air compressor is not a deliate piece of equipment, and as such, it is hard to break it down to the point where it is completely useless. With this in mind, plus knowing about the warranty, history of the machine, and any wear and tear on it, will give you a better understanding of what you are getting when you buy a pre-owned model. This purchase can be the best investment you could make for your business, so be sure to be diligent when it comes to buying your industrial air compressor.

Using an air compressor on a daily basis results in the buildup of moisture. Air compression creates collides hot and cold air within the system, causing water to condense, building up moisture inside the air compressor as a result. Any moisture within an air compressor system requires close and immediate attention.

Moisture buildup may be normal but it is not desirable. For example, water sitting on compressor parts can cause rust and create poor performance. Compressor parts can easily be harmed by carried moisture, such as freezing water on outside lines prohibiting their use.

Moisture buildup can also be harmful to the environment and to people who work around the compressor. Mildew and mold can form in any compressor, and both can cause illness. Bacteria gathering in standing water are usually more harmful than mold. Due to these possible complications, anyone who owns an air compressor needs to have a protocol or piece of equipment for dealing with water inside their compressor.

Larger systems can be equipped with air dryers that help control the moisture problem. There are several different types of air dryers for compressors; including refrigerated, desiccant, and deliquescent. All types are effective at preventing moisture build-up inside air lines, and your choice of air dryer should be determined by several factors, including the type of air compressor being used, the temperature of the ambient air, and the operating pressure of the compressor.

In addition to air dryers, air compressor owners can also use filters known as moisture separators to protect their compressor systems. Moisture separators are relatively inexpensive, considering how many costly repairs they avoid. They are easy to install and maintain, although they must be regularly drained due to the moisture they accumulate.

A good way to prevent moisture damage to your compressor and your product is through taking precautionary steps to reduce moisture. This can be done through draining your air compressor’s receiver often or adding a larger receiver, which will cool air passively. In an environment in which the temperature is controlled, your air compressor system will be less susceptible to moisture accumulation. Proper preparation and planning, along with routine replacement of filters, will also help control moisture levels. Following these suggestions can help you avoid most of the problems caused by moisture.

Compressors are used in industry for many different reasons and jobs. Basically, they are machines that increase the pressure of a contained gas by reducing its volume. This means that they push a lot of gas into a smaller space by compressing it and release it at different pressure levels when necessary.

The industrial rotary screw compressor works by using two screws which push the gas into a chamber, from where it is later released with greater pressure. Oil-filled rotary screw compressors use oil for a smooth, silent run, and also to act as a seal when pushing the pressurized gas into the release chamber. They are used in construction sites to operate air driven machinery. Dry screw compressors do not use oil and increase pressure in the chamber with the screws, which are aligned perfectly with the walls of the air end and do not allow air to escape.

The oil-filled compressor is more effective and produces a greater volume of air because of the seal that is formed by the oil in the chamber. An oil-free compressor will yield a pressure of 150psig and a gas volume of 2000 cubic feet per minute while an oil-filled model will yield 200psig in pressure and a volume of 1500 cubic feet per minute (both volumes and pressures are measured at 60 degrees Centigrade and atmospheric pressure).

The rotary vane compressor works with a bladed rotor. The decreasing spaces around the blades of the rotor as it rotates produce the volume decrease in the gas, thus creating pressure. These compressors are found in two different models: dry and oil-filled. The oil-filled compressor is the most effective and can reach levels of 90% efficiency. Much like the rotary screw compressor, the oil-filled model produces more pressure than the dry compressor.

These two compressor types are similar in their uses and functions; their technology is also much the same. They both run on fuel or with electric motors. They are both extremely quiet and the oil-filled versions can produce excellent amounts of continuous pressured air. The dry models are also effective but their yield in pressure decreases because of the lack of the oily mechanical seal. They are both built in different sizes with different functions which depend on the compressor size. Rotary screw and vane compressors will do the same job effectively but the screw type produces air more efficiently over the lifetime of the compressor.

Removing condensate is extremely important for maintaining the appropriate air quality level in air compressors. Condensate is the moisture that collects out of the air compressor as the air is cooled. It is crucial that this byproduct is removed from the compressed air system, due to the damage it could cause to the entire machine. Any moisture in the compressor system could lead to the growth of rust or mold in the compressor or piping. It could also damage equipment, tools or accessories connected to the compressor. Additionally, because it can be carried in the air flow, condensate may reach and ruin any products that are being manufactured. There are multiple ways to remove condensate.

With manual operation, the operators manually open valves to discharge condensate. This method depends on people opening valves at the appropriate time for the necessary amount of time. It also leads to excess loss because air escapes when the valves are left open to drain the condensate.

Level-operated mechanical float traps use a float connected by linkage to a drain valve that opens when an upper setting is reached and closes when the drain is emptied. This convenient method is best suited for a fully-attended powerhouse operation with scheduled maintenance. However, it is more prone to blockage from the condensate, as well as getting stuck in open and closed positions.

Next, there are solenoid-operated drain valves that can be used to manage the condensate. These valves have timing devices that can be set to open for specific amounts of time at pre-set adjustable intervals. This is a very convenient method. These valves also require strainers to reduce contaminants. Contaminants could potentially block the inlet and discharge parts of these devices.

Finally, zero-loss traps are considered to be one of the most reliable ways of getting rid of condensate. These traps have a float or level sensor that operates an electric solenoid or ball valve to maintain the condensate level in the reservoir below the high level point, or a float activates a pneumatic signal to an air cylinder to open a ball valve through a linkage to expel the condensate in the reservoir to the low level point. Basically, this method wastes no air and is very reliable.

Obviously, there are many methods to deal with air compressor condensate. Removing condensate is a very important part of air compressor maintenance and upkeep. As long as you remove it, your compressed air system should stay in great shape!

Anyone who runs an air compressor normally monitors the temperature. If you do, and you use mineral oil, then you probably know the oil tends to run hot at times. As a result, then you are probably spending more money than necessary due to frequent oil changes. By switching to synthetic oil, you can save not only finances but you will also extend the life of your air compressor. This article will address the pros and cons of both mineral oil and synthetic oil. 

However, one of the main downsides of switching from mineral oil to a synthetic version is that you must take the compressor apart and clean it thoroughly to get all the mineral oil out. Still, the advantages of synthetic oil far outweigh the use of mineral oil. Synthetic oil comes with a host of benefits including: extension of your compressor’s lifespan, reduces the amount of oil the compressor uses, energy conservation, decreased oil for disposal, reduces the amount of maintenance you have to do to your compressor, and synthetic oil can increase the life of every part in your compressor. 

The initial cost of purchasing the oil is far outweighed by the fact that synthetic oils facilitate increased operational, economical, and even environmental benefits. The factor that probably saves the most money is extended drain intervals. Synthetic oil has outstanding oxidative and thermal stability, which means that on average, if you were getting 1,000 hours of usage with a mineral oil, you will get somewhere between 8,000 and 10,000 hours when using a synthetic. 

As if these factors weren't enough, one must also consider the fact that using synthetic oil will reduce deposit formation in your compressor, works at lower temperatures, is more resistant to fire, and has better low temperature fluidity. Synthetic oils are more energy efficient, and although this aspect of savings is far overlooked, if you run your compressor a lot, you can save up to 650 dollars per year from the switch. It is clear that the savings that result from the switch far outweigh the initial costs.

Industries that do heavy duty work need industrial air compressors that are durable and efficient. Keeping these compressors running properly can save businesses time, money and aggravation.

There are many signs that will tell you if your air compressor is faulty. Troubleshooting and noticing problems before they get worse can prevent you from having to incur financial costs from either repairs or replacement. Oil in the discharge, fuses that constantly blow, and overheating are some of the most common problems industrial air compressors have, and they tell you that you should service your air compressor soon.

These small problems are often easily fixed. Too much oil consumption, for example, can be caused by defective or clogged filter or leaking oil lines. Replacing the filters can be an easy fix for the compressor problems. Tightening bolts and having the system's gasket replaced can also fix the oil leaks. Worn piston rings can also cause oil consumption.

For fuses that blow repeatedly, take note of the ampere rating of the unit to make certain that the right fuse is being used. If you are using a correctly sized fuse and it is still blowing, the motor is probably being overloaded. This is a larger problem that needs to be taken care of. It is best to turn off the machine to prevent more damage.

Compressor overheating can be caused by poor ventilation. Checking oil levels and blowing out coolers can prevent over heating problems. Oil discharge in air coming from the compressor is another common problem. It can be a sign of improper installation of parts or faulty components. If you perform regular maintenance checks, you can easily find and correct these problems as well as give you ideas of problems areas your compressor tends to have.

Once you inspect the compressor and see if it is an easy fix or not, then you will know if you need a repair specialist. When it comes to repair specialists, background checks are important, because having a technician without enough experience can lead you to paying more money. If you do your research well, though, your compressor will be reliably fixed, and all you have to do to avoid future problems is properly maintain it.

When choosing an installer for your customized compressor system, there are several factors to take into consideration. Some of these factors can include the quality of service, the price, professionalism, the reputation of the company, and more. It is always a good idea to do your research before hiring a company you are planning to do business with. It is ideal to have a professional company with extensive knowledge of the product install your compressor correctly to avoid any complications with your new system down the road.

There are a lot of different companies to choose from when it comes to installing your customized compressor system. You certainly want to make sure that you select one that will suit your requirements, needs, and budget.

It is a good idea to go with a professional company that has a reputable name. Ideally, you should also look for one that is not only affordable, but is also highly rated in customer service and available to answer any questions that you may have in regards to their products or services. A reputable company with great customer service should be your top choice when selecting an installer.

When searching for an installer, there are a number of factors to consider. First, make sure that the installer is experienced. Without any experience, the installer may not do a good job with your compressor system. While checking on the installer’s level of experience, you should also ask to see some of their previous work. Not only will this help you verify that the installer is indeed experienced, but it will also give you a better idea of what quality work they do. The last thing you need to happen to your new industrial air compressor system is for it to break down due to bad installation, so quality of work should always be priority number one.

Next, make sure that the installer has the necessary and required licenses and insurance. It is also a good idea to find out if the labor and materials are covered under a warranty.
Without a doubt, when considering having your compressor system installed, it is very important to hire a professional, reputable company. This will not only save you money, but your precious time and frustrations as well. Go with a company you can trust, and your compressor system installation will go smoothly and be in service for many years.