• How to Choose a Filter for Your Industrial Air Compressor

    Filters are a very important part of your industrial air compressor system. Filters serve to remove contaminants and purify the air within your system. Choosing the right type of filter depends on the amount of maintenance you wish to engage in and the requirements of your system.

    Oil flooded screw compressors are a highly regarded, cost-effective, reliable system. However, oil flooded screw compressors need the proper filter to remove the oil and contaminants introduced to the compressed air. Appropriate filters include coalescing filters, which remove oil mist, as well as automatic drain valves that eliminate liquid condensate. Both filters need to be replaced when filled with dust.

    Air compressor systems need aerosol filtration at each point of use, from upstream, after the air dryer and downstream. Desiccant and refrigerated dryers need to utilize both a prefilter and afterfilter to remove liquid and particulate aerosols. Filtration units also prevent adsorbent fouling in desiccant dryers as well as the fouling of heat exchangers within the refrigerated dryer. The downstream filter is responsible for removing the adsorbent lines from the desiccant dryer and water mist from the refrigerated dryer.

    Choosing the right compressed air filter depends on your system’s needs. A high particulate filter operates under high temperatures and offers a high level of protection against fire in a heated desiccant dryer. Vapor or charcoal filters are suggested for removing organics from chemical vapors and hydrocarbons. Particulate filters are used in desiccant dryers to remove scale, metal oxides and desiccant particles.

    Compressed air filters are necessary to maintain clean air as they remove hazardous materials from the unit. Particulates to watch out for include metal oxides, dirt and scale since they can damage finished products, erode system components and generally decrease efficiency. Chemical gases such as sulfur, carbon dioxide, carbon monoxide and chlorine need to be filtered since they can threaten the health and safety of workers. Fungus, microbes and mold can grow within a moist air system and produce a corrosive acidic waste. This causes pipes and valves to clog with sludge.

    Finding the right filter for your industrial air compressor can increase your unit’s efficiency and lower energy costs.

  • Industrial Air Compressor Accessories

    If you are using an existing industrial air compressor or plan on purchasing one in the near future, you may also want to consider what industrial air compressor accessories you will need. Accessories that you may want to consider for your industrial air compressor include air mufflers, vibration isolation pads, drains, and filters.

    The first accessory that you may want to consider purchasing is an air muffler. Air mufflers work much like the muffler on a vehicle in that it works to reduce the sound of the air that the air compressor forces out. Another accessory previously mentioned are vibration isolation pads. These pads aid in absorbing the force of the air compressor when in use by sitting beneath the air compressor and absorbing vibrations, thus promoting more stability.

    The last two mentioned accessories are perhaps the most useful for your industrial air compressor. Having a drain on your compressor gives you the opportunity to drain condensate from you system. This condensate, if not removed, can cause harm to your system and in the end have long lasting, damaging effects on your industrial air compressor. These drains also allow you to release this condensate without losing valuable time with your system by having to shut it down. The other accessory that is vital for the smooth operation of your compressor is a filter. An air compressor filter works to keep debris in the air that you may not even be able to see from entering in the compressor. This is vital so that the inner workings of your compressor stay clean and thus work better.

    The current trend in industrial air compressor accessories is that they increase productivity and are energy efficient. All of the accessories mentioned may help your air compressor increase productivity, save energy, and last longer by protecting important components of your air compressor.

    There are many different brands and sizes of air compressor parts. When choosing the right one for your industrial air compressor, you need to check your air compressor to see what is compatible with you brand, size, engine, etc. Keep in mind that you may want to check multiple dealers to be sure that you get the best deal and the best service. Always have your compressor model number and other information with you when making a purchase, to make sure that you have all the information you need to make an informed decision.

  • Learning How Compressed Air Works

    Compressed air is a simple mechanic that can be used on the work site, in a factory setting, and is used to power a host of different tools. Despite having been developed decades ago, compressed air is still alive and well, and is being used in many different settings. It is widely used both commercially and residentially, but the primary focus of a large, industrial sized air compressor is the factory setting.

    Just like your car engine, pistons push down on an air and gasoline mixture that compresses it inside a tank. In your car, the mixture is then heated and ignited to produce the hot air needed to produce power. Similarly, in an industrial air compressor, a piston pushes down on the air inside a tank, pressurizing it. The tank itself is able to store a large amount of compressed air, ready to be used at any time for any number of different tools.

    Air compressors are extremely versatile and as such, the industrial world requires them for many different things. For instance, air compressors are used to power a host of air driven tools such as paint sprayers, sanders, belts, drills, pneumatic tools, and more. These are especially common in automotive or auto body shops where compressed air is used to power almost every tool there, including lifts. Commercially, compressors can be used in the home and are used to inflate tools, pools, car tires, and even powering smaller, commercial sized pneumatic tools. Due to the advancements and developments of technology, the demand for these industrial air compressors has grown, and the prices for them have gone down over the years. The tools for these air compressors are sometimes bundled into a package and sold with them, or easily bought locally. Pressure washers are a great example because they consist of an air compressor and a garden hose attached, combining pressurized air and water to make pressurized water. These pressurized washers are great for cleaning concrete, cars, siding, and decks.

    Consumer electronics, especially computers, are also utilizing the powers of compressed air. Due to their static nature that attracts a large amount of dust within them, compressed air is used to clean many computers of dust and other particles. These mini compressed air cans are an ideal way to clean your computer and can be found virtually anywhere.

    The technology involved in industrial air compressors has been dramatically upgraded over the decades. Air compressors can be made to very specific measurements, improving on already existing parts, and keeping maintenance on these machines low.

  • Preventative Maintenance for Industrial Air Compressor Systems

    Maintaining the efficiency, capability, and cleanliness of an air compressor system is of vital importance when running a business that requires one. Understanding that typical air compressors have schedules of maintenance, the procedures for handling each specific maintenance intervals is extremely important in taking care of an air compressor, and can help prevent problems before they begin. Neglecting to adequately maintain an air compressor could have disastrous effects on product safety, energy costs and unscheduled compressor down time.

    When assessing the importance of preventive maintenance for an air compressor system, the first factor will always be cost. Costs can skyrocket when maintenance related efficiency is poor, for example a 100 horsepower motor that drops pressure output by even 4 psi can lead to thousands of dollar in increased energy costs per year. Scheduled maintenance will often diagnose and fix such inefficiencies by allowing for baseline measurements to be taken regarding output at regular intervals. Reduced outputs can be handled and overall system problems can be solved before energy costs increase, or products begin to suffer.

    Many who do not undertake preventive maintenance also fail to realize the impact it can have on product contamination. Filters that are designed specifically for certain pressure ranges often fail when output is lowered due to poor maintenance, and particulates that were normally caught in the filter make it into products, significantly reducing quality. This can further impact costs by loss of product due to quality issues.

    Routine maintenance should be performed consistently to assist in diagnosing problems and alleviating down time. One would do well to note that this procedure is not exactly the same for any model, and many units come with specific maintenance plans that should be followed to the letter. With that said, before beginning a maintenance plan, always be sure that the power is off, that any sources of power to the unit are locked out, and that all pressure in the unit is exhausted. Failure to do any of the above can result in system damage or personnel injury.

    A good maintenance plan can be performed as often as daily or weekly and requires a basic check of the compressor and accessories. Any unusual vibration or noises should be noted during these checks as well, and excess moisture should be drained from the tank drain valve.

  • Choosing Between Single Stage and Two-Stage Air Compressors

    From outdoor construction equipment to indoor industrial factory work, industrial air compressors are used to power the largest and most useful machines on the worksite through its system of compressed air. When dealing with large scale, industrial sized air compressors, there are two main categories that you want to look into before making the final purchase: single stage air compressors and two-stage air compressors.

    The biggest difference when determining which stage air compression you want lies with how much pressure you want to get out of your machine. The compressed air that is expelled from the unit comes out at a high PSI, or pounds per square inch. This unit of measurement determines how powerful and how large of a tool can be used in conjunction with the air compressor machine.

    An application that requires 125 PSI or below can usually be handled by a single stage industrial air compressor. These compressors work by pulling air into the chamber and compressing it by reducing volume but keeping its mass, creating a large amount of pressure buildup. This pressure is then expelled via a pneumatic hose which connects to your power tools, giving you clean compressed air to run all your necessary equipment.

    For anything requiring more than 125 PSI, a two-stage air compressing unit is required. Working through virtually the same principle as the single stage compressor, a two-stage compressor unit compresses the air a second time, creating even more pressure in the unit to be expelled.

    Another measurement you need to take into consideration is CFM, or cubic feet per minute, which determines the amount of space that the compressed air will take up. A larger CFM means that more compressed air can be expelled at a higher pressure, allowing for multiple tools to be connected to the compressor.

    A single stage compressor is best used for smaller jobs or work sites where the duration of the job or the amount of tools being connected is low. For much larger jobs on larger sites, a two-stage compressor is required because they will have the necessary CFM and PSI to get all your tools working in top shape.

    It is important to consider these factors when purchasing an industrial sized air compressor. Each one has its benefits and each one has its specific uses. Determining which one works best for your business is vital to getting the most for your money, so be sure to check out an established, reputable air compressor dealer for more information on single and two-stage air compressors.