Industrial air compressors are heavy duty machines that are used by a variety of industries to supply power to run tools and machinery. They feature an airend that compresses air, and this can be used to supply the energy that is needed to move machinery such as construction or fabrication equipment. Buyers need to be aware of several issues that are associated with these machines, and this ensures that they will purchase the proper machines for their needs.

Businesses often choose to power machinery and tools with compressed air. This offers a number of benefits from other choices, and industrial compressors can supply equipment and machinery with a steady supply of air power.

Consumers should be sure they purchase the right product for their needs, and there are several things to keep in mind before making a purchase. The primary component that is used to buy an industrial air compressor is the amount of air that is needed to run machinery or other tools. Compressors are variable in the amount of air that they can supply, and buyers need to research the needs of their machinery before they make a purchase.

There are also several different products on the market, and they are known for their differences in the way they compress air. Industrial rotary screw compressors are one of the most common types, and they feature energy efficiency, low maintenance and low noise. Rotary lobe blowers are another option, and these machines are best for air knives, waste water treatment and pneumatic conveying. Portable compressors are the machine of choice for those in the construction industry. Most of these are affixed to a trailer and are designed to be towed behind a vehicle.

There are a few maintenance tasks that are essential for ensuring an industrial air compressor lasts for as long as possible. The tanks that are used to hold air should be drained on a regular basis. There is a lot of water that can accumulate in these tanks, and draining will ensure the tank lasts. Another issue has to do with filters, and these should be changed on a regular basis. This prevents dirt and other debris from ruining the parts that are used by the machine to compress the air.

Air compressor emergencies can be very serious, resulting in personal damage and the breakdown of equipment. It is crucial that anyone involved in the process of compressing air is trained and aware of potential dangers. If you are working in an area you are unfamiliar with while using an air compressor, then take some time to look around for potential hazards, ask the owner questions about what is in the area you will be working. When operating an air compressor, be sure to read the handbook before using it. Follow the instructions precisely as each unit can vary.

When compressing air, keep the air pressure at the manufacturer recommended level. Check the gauge regularly and ensure it is working as intended so that you do not get a false reading. When operating an industrial air compressor it is important to use a hose reel, especially if your company has multiple air tools. This helps keep the work place more organized and efficient, essentially preventing wear and tear on the hoses. Hose reels also function to prevent tripping hazards, avoid air leaks and increase the overall productivity for the staff.

Not only can air leaks present a safety hazard, but can also cost a company potentially thousands of dollars a year depending on the size and amount of leaks. Therefore, identifying them as quickly as possible is crucial. Some signs of an air leak are; hissing sounds, lack of air pressure, the gauge reading an amount that is not equal to the amount used, and/or lack of air flow.

When dealing with an air compressor malfunctions, it’s crucial to be aware of back-ups and rentals available to you. Using qualified staff or sub-contractors to conduct regular maintenance on the air compressor units, a scheduled walk through and inspection of all the involved equipment can prevent leaks, fires and help make the units more efficient. There are many different condensate management devices, including zero loss drains, timed automatic drains, and oil/water separators that can help you lengthen the service life of your air receivers and lubricants by removing condensate efficiently, and keep you in compliance with regulations regarding condensate disposal. Make sure that repair technicians are up to date on the latest aspects of repairing, rebuilding and maintaining a wide range of equipment.

An industrial air compressor is a machine that is used to convert power into energy by pressurizing and compressing air, which is then released in quick bursts. There are numerous methods of air compression, divided into either positive displacement or negative displacement types.

Compressed air is commonly used in industrial settings as a form of power output. It is used in equipment ranging from pneumatic equipment to engines. Most warehouses have their own air compressors, to speed equipment repair. Mechanical devices can be attached to an extended hose, and the power of compressed air is utilized to drive nails, run rotary gadgets, and even power forklift engines. For industrial applications, a small commercial grade compressor will not cut it. An industrial shop is going to want an industrial sized air unit, with a large air tank and powerful compressor.

Unfortunately, top quality industrial sized air compressors can be quite pricy. This is where strategic thinking becomes important. Some businesses have the cash to afford huge and brand new models of industrial air compressors. An independent business will likely focus on economy, which would mean making do with smaller units or hunting down a used model.

Pre-owned, or used, air compressors are a great way to save money. Not only will you be able to purchase an air compressor at an affordable price, but you will also be able to get a quality piece of equipment. Used or pre-owned equipment can be less expensive because it has already depreciated in value or is no longer required by the original owner. However, this reduction in price does not translate to a reduction in quality. Most pre-owned industrial air compressors are in great shape, run smoothly, contain all the necessary parts, and operate efficiently. In fact, many of these pre-owned models are still under warranty, which reduces risk to the buyers.

Air compressors are not sensitive equipment, and it is still possible to find replacement parts for most models. Those made by a established reputable manufacturer can last for decades. Many used air compressor models will still operate to their original specifications. It is generally the accessories that need replacement or better maintenance. These accessory parts are easy to come across to replace some of the worn out, depreciated ones found on pre-owned industrial air compressors. Purchasing a pre-owned air compressor is a terrific way to save money on a great quality machine.

If you are searching for a way to get harmful moisture out of your compressed air system, a refrigerated air dryer may be the most efficient solution to your problem. Too much moisture in your compressed air system can slow the performance of your machine and potentially destroy it, costing you time and money. A refrigerated air dryer removes detrimental moisture from your compressed air system by cooling the moisture until it is compressed into droplets that are then drained away. Using the refrigeration system has several benefits that cut energy costs. Cycling and non-cycling refrigerated air dryers are available depending on if you have a small air system requiring less horse power or a larger system requiring more horse power.

The desiccant air dryer is the most common air dryer because they have been around much longer than the newer energy saving ones. The desiccant dryer uses more energy by passing compressed air through a pressure vessel where the air is brought down in temperature so the water vapor does not condense. The refrigerated air dryer functions to reduce your energy cost, by using two heat exchangers. The two exchangers use cold incoming air to cool the hot incoming air, making it possible to use a smaller compressor, essentially reducing the energy consumption. A refrigerated dryer also takes a lot of the work load off of the desiccant dryer, saving on energy costs and giving the desiccant dryer an increased lifespan and greater reliability. Most compressed air systems do not come with a stand-alone refrigerated dryer; they are most commonly used to coincide with a desiccant dryer.

Giving a desiccant air dryer a longer life span with the assistance of a refrigerated air dryer, may be ideal for your budget. If you are interested in cutting energy costs and managing a more energy efficient hybrid dryer that saves you money in the short and long term, you may want to appease your compressed air system by adding to it the latest and most innovative technology. The U.S. Department of Energy estimates that about ten percent of all energy generated in the United States is used by air compressors. These statistics also indicate that about half of this energy is in fact wasted. Refrigerated air dryers work to reduce the harmful effects on the environment by diminishing wasted energy. Reliability coupled with saving money, while lessening the impact of industrial waste, contributes to overall satisfaction.

Anyone who owns an air compressor understands the importance of properly maintaining their machine. A crucial tool in this process is a condensate management system. So long as these systems are functional, they are very important components of all air compressor systems because they separate the small amount of oil from the condensate that gathers in the air compressors. This allows the caretakers of the air compressor to perform simple, ecological, and economical disposal of any leftover waste.

Since unwanted and excess oil can be a serious problem in an air compressor system, oil and water separators or condensate managements systems are installed to reduce the waste oil concentration. However, before disposing of this oil into the sewer, you must make sure to reduce it to legal limits. If you do not do this, you could be harshly punished for disobeying the law and potentially poisoning the nearby environment. Most separators naturally reduce the oil to a level permitted for disposal, but always check with your local municipality to be sure everything is alright. It is also good practice to periodically send out a sample of the reduced oil for analysis, in order to be confident that you are correctly following the rules.

In the past, people would use a waste management company to come and remove collected condensate from their site. This, however, came only at a considerable cost. Today there are a number of different types of condensate management systems which can used independently within a company, and can separate almost any compressor fluid from the condensate. This allows the 98% of the condensate that is solely water to be disposed on site. The small percentage of remaining oil can then be collected and recycled, or disposed of at a much cheaper rate than what was possible before.

When one owns an industrial air compressor, there are many benefits of using a condensate management system to maintain and clean it. One of these benefits is that these systems will protect your air compressor from damage by removing harmful excess oils. You will also ensure that the compressed air that is being delivered to your company is clean, protecting your product from any possible harm. You will also be saving a great amount of money in waste removal and fines, because you can clean your air compressors without the help of a second party. Finally, condensate management systems allow companies to be environmentally conscious and safe during waste disposal by removing any toxic oils from water that could otherwise be safely drained into the environment.

When it comes to powering pneumatic tools, factory equipment, or heavy machinery, compressed air is one of the best sources of energy. In order to utilize the power of compressed air in a large, industrial setting, you are going to need an industrial size air compressor. While there are many standard types of industrial air compressor available, getting a custom made one might end up being the best option for you.

There are two main types of industrial air compressors: positive air placement ones and dynamic type machine ones, in which they automatically increase air pressure, as well as elevating the air to a higher pressure. The types of industrial air compressor are further broken down into reciprocating, rotary screw, and rotary centrifugal systems.

Rotary air compressors use two rotors within a casting device which compresses the air internally in the system. These machines use a rotary system of positive expulsion to move pressurized air throughout the machine and into connecting hoses, where it is expelled at high pressures, providing compressed air energy. Rotary air compressors contain no valves in the system itself and are often oil cooled, so be sure to take the proper preventative maintenance steps when it comes to keeping your rotary air compressor running efficiently.

Another type of industrial air compressor you could use is the dynamic air compressor, which produces a high amount of air pressure from the conversion of angular momentum imported by a rotating impeller device. Again, always be sure to take the proper preventative maintenance steps when dealing with a dynamic air compressor, as it is important to check this impeller device on a regular basis to make sure that it is still functioning at its normal, high efficiency capacity. One of the advantages of a dynamic air compressor is that it allows for a high capacity of air to run through the system because the flow through the compression chain, and the entire system itself, is continual. These industrial air compressors are built oil free and therefore make them easier to maintain then their oil cooled counterparts.

These are just a few of the different types of industrial air compressors available on the market. A customized one will allow you to mix and match what you want in an air compressor, such as what expulsion system, what drying system, what cooling system, and so on. Be sure to research the product you are looking into from a reputable, established industrial air compressor dealer.

Moisture is the enemy of industrial equipment that uses compressed air to function. In order to maintain and protect this often expensive equipment, this moisture is removed by industrial refrigerated air dryers. Here’s a brief overview of how industrial refrigerated air dryers work and how they are used.

Compressed air results in a concentration of atmospheric elements such as water vapor. Condensed air will condense moisture within the pipes which transport the air away from the compressor. This excessive moisture in the compressed air can cause several problems such as corrosion of equipment, freezing of the air lines that are outdoors, and depositing minerals and other elements throughout the equipment.

An industrial refrigerated air dryer eliminates this moisture by means of a process that helps to filter and collect the water vapor and then drain it from the air lines. Product specifications for refrigerated air dryers found online suggest that there are two circuits at work. They also note that this industrial refrigerated air dryer delivers a dew point of about 35 degrees Fahrenheit. Refrigerated dryers employ two heat exchanges, air-to-air and air-to-refrigerant. This process causes the moisture in the compressed air to condense and then the system allows the liquid to be drained away. The outgoing air is then warmed by the air-to-heat exchanger to preclude the outside of pipes from sweating.

The other part of the process involves the refrigeration compressor pumping high pressure refrigerant into the condenser of the unit. This transfers heat from the refrigerant gas to the ambient air when the gas turns into liquid. The refrigerant enters the air-to-refrigerant heat exchanger where the hot, compressed air is absorbed into the cold refrigerant and this further reduces the water vapor and substances.

Industrial refrigerated air dryers are used in industrial settings that require dry, compressed air. Industries that use pneumatic control systems and pneumatic tools will realize the benefits from these industrial refrigerated air dryers, which goes hand in hand with proper maintenance needed for all industrial tools.

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.

Designing a new compressed air system includes hiring a professional engineer to complete an Air Demand Analysis to customize the system according to your needs and usage in order to optimize performance and efficiency. The professional engineer will perform a series of tests and use that information to create a detailed analysis, which will help develop a compressed air system for you that has environmental, energy, and cost benefits.

Accurate and valuable data will be gathered throughout the process that will be used to optimize your system. Air consumption profiles will determine which system is best suited for your operation. Everything including the type of compressor and its layout is completely tailored and designed case-by-case. This step is highly recommended due to the amount of energy savings it guarantees, which translates into a significant amount of money saved over time.

Energy costs can be significantly reduced when an Air Demand Analysis accompanies a new system. This is significant because electricity is by far the highest cost of operating it. The goal of the process is to meet all your requirements while keeping the amount of pressure used to a minimum. This is achieved by matching you with the appropriate device and then customizing its features and layout.

The Air Demand Analysis consists of a few steps. First, air demand and other data is collected. Second, that data is used to appoint the best systems. Third, each system is tested vigorously to determine its power consumption and overall efficiency when faced with the variables of your working operation. Fourth, the best system is selected and then tailored to fit. It is even possible for you to view a detailed 3D image of your system before it is installed.

The professional engineer will be able to provide a realistic prediction of energy savings. You will have the opportunity to compare the extremes of having an Air Analysis and not having one to get a true picture of its necessity. The best systems are durable and have optimal performance. The professional will do everything to ensure you have the best system.

An Air Demand Analysis is a very important step when designing and selecting a compressed air system. A professional engineer or vendor will perform tests to determine the system that will perform best in your environment and save the greatest amount on energy. It will be completely designed and tailored to your needs to ensure maximum performance, reliability, and efficiency.

When it comes to removing contaminants from your industrial air compressor system, there are two primary types of dryers that are used: desiccant dryers and refrigerated dryers. Each one of these different types of dryers has its own practical purpose, and each one is effective at removing moisture, condensates, and contaminants from the air.

Contaminants build up in the air compressor system when air is heated through the compressor machine before being pushed out in the form of energy. This heat allows moisture, such as water vapor, to begin building up in the system. On top of the moisture, liquid and non-liquid contaminants, such as oil and dust, will also build up. Removing these condensates is a vital step in the industrial air compressor maintenance process.

A refrigerated dryer is the first type of dryer that can be used. This device runs on the simple premise of condensation. By cooling the air as it passes through the valves in the system, moisture droplets that contain water vapor, dust, oil, and other contaminants will be drained into a large tank or an external unit.  These dryers come in two forms, cycling and non-cycling, and the appropriate dryer to use for your system will depend on its specs and your individual requirements.

A desiccant dryer is the alternative to a refrigerated dryer, although desiccant dryers have been around for much longer. In this system, the compressed air is not cooled, but instead passes through chambers of disiccants which are moisture removing packs that absorb water vapor and contaminents in the water vapor. These packs can be easily disposed and replaced with routine maintenance, and are a great way to keep your industrial air compressor running in top shape.

When it comes to saving energy, desiccant dryers are always a smart choice because they do not use much additional power compared to the refrigerated dryers. However, newer and better refrigerated dryers are becoming available that use heat exchangers to cool the air to optimal levels and not overcompensate for the air outside the system. This allows the energy costs of a refrigerated dryer to remain low, while also keeping maintenance and repair costs down.

A final possible solution to saving energy while still removing contaminents properly and throuroughly is to use a combination of both a desiccant and refrigerated dryer. The desiccant dryer will remove any moisture from the system in the intial stages of compression, while a low-power refrigerated dryer is used to finish the job down the line. By utilizing this system, not only do you save money on the maintenance of both dryers, but the low power refrigerated dryer will keep energy costs down, saving you and your business a great deal of money.