• Heavy Duty Industrial Air Compressors: What They Are and When They're Needed

    Heavy duty industrial air compressors are devices that collect air from the surrounding atmosphere and turn it into stored energy. They do this by gathering, compacting, and condensing the air to a high pressure. Later, when the compressed air is released and expands back into the atmosphere, it creates a great deal of force.

    There are many different applications for industrial air compressors. One of the most important of these uses is to provide a power-source for pneumatic power tools. These are tools like hydraulic hammers, wrenches, drills and saws. With these tools, many normally long or difficult tasks will become very simple and quick. Pneumatic tools are essential in a number of different fields, like assembly line production, agriculture, and automobile production. Because of their power needs, these industries require the reliable and convenient power source compressed air provides.

    Compressed air in itself is an essential part of production for many industries as well. They rely on air to make and form some of their products. In plastics, for example, compressed air is used to fill and expand bottles and containers into their intended shape, and compressed air is indispensible for running pneumatic tools.

    If a business needs an air compressor, there are many things that will need to be taken into consideration before making a purchase. First and foremost, it is important to consider what the air compressor will be used for, as well as the volume and pressure required from the compressor. This will make it easier to select the most appropriate kind of air compressor for the needs of the business. Additionally, an air compressor should only be purchased if there are spare parts readily available for it. This ensures that, if some part of the compressor breaks later one, it will be easy to repair it. If the business's needs and compressor options are researched beforehand, the proper compressor selection is easier. In this way business can find the right kind of air compressor, and will be able to do the jobs expected of it.

    If a company finds that they need more power, a heavy duty air compressor could be a wise choice. It can provide mass quantities of readily available and cost-effective energy, and will help production move much more quickly. So long as a heavy duty compressor is well-kept and correctly used, it will be an excellent long-term investment for all types of businesses.

  • Finding the Right Air Dryer for Your Air Compressor

    Pneumatics is a form of industrial technology that employs pressurized gas in order to do work. The jackhammer you hear being used to tear up the street outside your window is a pneumatic tool. So is the spray paint system used to apply the finish on your car and home appliances. Today, pneumatic systems power everything from dentist drills to sand blasters and they are a true modern marvel.

    Pneumatic tools and machines rely upon air compressors to fill up a tank with compressed air -- in most cases, the very same air that we breathe. The problem with this is that common atmospheric gas (air) contains a lot of moisture in the form of water vapor. The more you compress the air, the more condensate you generate. Pneumatic equipment can be very sensitive to moisture contamination, and when water gets inside a compressed gas system it can wash contaminate lubricants put there to protect the compressor cylinders from wear. Some industrial grade pneumatic systems can collect as much as 18 gallons of liquids in the form of water vapor and contaminants in a day.

    Removing unwanted water vapor from a closed pneumatic system requires an air dryer; something that can keep the humidity out of the machine so that it can't corrode the tools or spoil the work. To accomplish this, the industry employs compressed air dryers which are systems designed to take moisture and contaminates out of compressed air before it can harm the metal system.

    There are three basic types of air dryers for air compressors. The most common type of these works by cooling down the air supply using refrigeration methods. When you reduce the temperature of air, water vapor in it condenses into liquid water where it can easily be drained away. Cooling hot compressed air is an extremely effective way to deal with the problem of water vapor in your lines, but the method can be energy intensive.

    Another type of air compressor drying system works by passing compressed air through a pressure vessel containing an absorbent material such as silica gel which can trap water vapor and keep it out of the compressed air system. When this absorbent material is filled to capacity the vessel can be purged and reused. In some of these units two vessels are used so one can be purged of water while the other one collects it. These systems are known in the industry as desiccant dryers, and when you employ a dual vessel system, you can go a long time without any interruption.

    The third variety of air compressor air drying technology uses a dehumidication membrane, which rids compressed air of water vapor as it is being produced. It uses a multiple-step process that begins by screening gases through a fine coalescing filter before sending it through some hollow fibers in the membrane bundle where the water vapor can finally be vented outside in the atmosphere. Membrane type air dryers are quiet, reliable and do not require any outside power source to operate. Many are designed for continuous 24 hour, 7 day a week operation where no maintenance is ever required outside the changing of cartridge or two every year.

  • Proper Maintenance for Your Industrial Air Compressor

    A large, industrial size air compressor is a piece of machinery that can be invaluable to the workplace, as long as it is running properly, Regularly scheduled maintenance is the best way to ensure that it is, and even though it might seem like there is a lot to check, going over everything now will save you time and money down the road. Your compressor will need to have daily, weekly, and monthly maintenance scheduled in order to keep it running, which can be as simple as checking the gauges for proper readings or removing and replacing filters in your unit.

    Checking valves and gauges to make sure they are working properly is a daily maintenance task.The daily inspection will also include draining the moisture traps, drop legs and receiver tank to release the water that has built up during use. Inspect the safety guards, valves, hoses and connections for leaks to ensure they are visually acceptable for use. Check the gauges on the pressure lubricating units. Every unit has an oil pressure requirement specific to the model and manufacturer. Operating temperature should also be checked regularly. This is also where you want to manage all your condensates, not just cleaning out the drop tanks, but also making sure that there is not any noticeable wear and tear on the unit from condensate buildup.

    A weekly maintenance schedule must be included on the maintenance checklist. This requires the maintenance staff to inspect and clean certain parts of the industrial air compressor. The pressure relief valves must be inspected for proper operation. Check for any air leaks and the air distribution system for any leaks. The compressor and coolers must be cleaned by wiping these components down and blowing out any dust or debris build up. Check the lubricant and change if necessary. The air intake filters must be replaced weekly.

    Every month the belt tension and/or coupling on industrial air compressors must be inspected. If the belts are loose, they must be tightened. If the belts are worn or cracked, they must be replaced. Inspect the electrical components, such as the contactor tips and brushes on the motors. Worn, burnt or melted contacts or brushes must be replaced.

    The biggest way to keep your industrial air compressor in top shape is through these preventative maintenance techniques. Daily, weekly, and monthly maintenance go a long way in keeping your air compressor running efficiently. Speak to an established, credible air compressor dealer for more tips and information regarding regular maintenance.

  • Getting the Right Filter for Your Industrial Air Compressor

    Whenever you are dealing with compressed air, it is important to note that it is not just the air that you are dealing with, it is also all the moisture, vapor, and contaminants in the air that you have to manage. In order to properly and effectively handle these airborne particles, you are going to need an industrial air compressor filter. However, choosing the right kind of filter depends on your system requirements and the maintenance you wish to complete.

    Choosing the right filter depends on your system needs, as some systems will require different types of filters or only fit certain types of filters in them. High particulate filters, for example, are used in high temperature situations, up to 450 Fahrenheit, and gives the air compressor a high level of protection against fire in a heated desiccant dryer. These particulate filters are used in desiccant dryer systems to remove scale, metal oxides, and desiccant particles. Then there are vapor or charcoal filters, which are used to remove organics from hydrocarbons and water vapors.

    There are many different types of industrial air compressors available. Oil flooded screw compressors, for example, are often highly regarded for their reliability and cost effectiveness. However, you still need to get the proper filter to remove all the contaminants from the air, such as oil and dust. Coalescing filters are ideal for removing oil buildup in the air systems, which combined with an automatic drain valve, can eliminate liquid condensates from the system. Always remember to replace the filters when they fill up with dust though, as this simple maintenance task can become a serious problem if not done regularly.

    These compressed air systems require aerosol filtration upstream of the compressed air dryer in order for the air to flow through the system clean and contaminant free. Dryers are used, both desiccant and refrigerated, to filter and eliminate any condensates or vapors in the air. Filtration unites will also prevent absorbent fouling in the desiccant dryers and fouling of the heat exchangers in refrigerated dryers.

    These filters are necessary to maintain clean air as they remove harmful materials from within the unit. Removing scale, metal oxides, vapors, moisture, oils, dust, and other contaminents is a must in order to keep your system running optimally. Organics such as microbes, mold, and fungus, as well as chemicals like chlorine, sulfur, and carbon monoxide need to be filtered as well, so ensuring this step of preventative maintence is always carried out should be a top priority.

  • Buying a Rebuilt Industrial Sized Air Compressor

    When faced with the options of buying an industrial sized air compressor, many businesses might initially stray away from buying a rebuilt model. However, due to the expensive nature of buying a brand new industrial air compressor, buying a rebuilt model is a cost effective method that still gives you a high level of quality from your machine.

    The most obvious and biggest benefit of buying a rebuilt industrial air compressor over a brand new model is the cost of it. The parts are going to remain the same, the function will remain the same, the efficiency will remain the same, but the rebuilt model will cost you half the price of a brand new model. On top of that, more often than not, when you buy a rebuilt industrial air compressor, you still get a warranty on the product, giving you some peace of mind when it comes to knowing when you next scheduled repair and maintenance will be.

    Aside from purchasing a rebuilt model, you might also consider buying some rebuilt components, such as filters or dryers. Particles and condensates are going to accumulate in your system whether or not your compressor is brand new or rebuilt, and dealing with them is of the utmost importance when it comes to ensuring the long life of your compressor. In order to deal with liquid condensates, you are going to need a dryer; either a desiccant dryer or a refrigerated air dryer. Both of these units can be rebuilt and installed on your air compressor, again saving you money but still giving you the same amount of function and use.

    The same goes true for buying a rebuilt filter, which will catch any airborne particles such dust, oil, and other contaminants. Again, buying a rebuilt filter that can be installed on your industrial air compressor is a money saving method of still getting the same amount of quality and efficiency.

    In order to get the best quality out of your rebuilt industrial air compressor or all its related parts, research units from an established, credible air compressor dealer. These dealers have all the knowledge and expertise when it comes to industrial air compressors, and they will make finding the perfect model to fit your worksite needs. Not only will they fit you with the right rebuilt industrial air compressor, but all the components that go along with it, ensuring that your air compressor runs as efficiently as possible.