Introduction

The air compressors are one of the necessary pieces of equipment in different industries to produce the compressed air for numerous usages. From use in operating pneumatic instruments and equipment to use in cleaning parts and surfaces, compressed air has become a basic requisite in manufacturing companies and factories. When it comes to choosing an air compressor, it is essential to consider which type and size can properly address the application needs while at the same time is reasonable in terms of cost. The complete guide to industrial air compressors will provide the reader with all the necessary knowledge on these devices and their application, functioning, types and what to consider when choosing them.

How does an Air Compressor Work?

An air compressor, in operation, pulls air into a storage tank and then compresses it with the use of pistons. The compressing mechanism can be positive displacement and can work through piston movement, or dynamic compression using impellers or vanes. Pre-charged air is used by other pneumatic systems downstream and the compressor continues to replenish the air in the tank. Any type of compressor will always contain some basics such as power source, intake filter, compressor pump, drive transmission, intercooler, air receiver tank, controls alongside the discharge connections. The majority of industrial air compressor factories use electrical motors with others using diesel or gasoline engines. The compressor pump may come in different types of technologies such as reciprocating, piston, vane, rotary screw, scroll, and centrifugal.

Maintenance of Industrial Air Compressor

An industrial air compressor is an essential tool that finds its way into many businesses and industries. Routine maintenance ensures that the compressor stays in good health and optimally functional while at the same time cutting down on its expenses. Use this piece to gain insight on how to properly care for your industrial air compressor.

• Clean and replace indoor air filters
• Cleaning of Oil and Oil Filters.
• Inspect and Replace Belts
• Check for Leaks 
• Keep Major Components Clean
• Inspect Hoses and Connectors
• Check Safety Valves  
• Monitor Operation and Performance
• Keep Components Rust-Free
• Service the Cooling System
• Follow Maintenance Schedules

Essential Tips for First-time Industrial Air Compressor Buyers

Selecting the appropriate industrial screw compressor for your business is an essential step; however, for any user who is going to make the purchase for the first time, it can be quite a challenge. So, here are the best tips that you need to consider as you choose the most appropriate air compressor for your work and pocket.

Determine Your Air Demand

First and foremost, pay enough attention to your real air demands concerning such indicators as cubic feet per minute (m³/min or CFM) and pressure levels (bar and PSI). In analyzing the impact of the compressed air system’s reliability, identify current uses of compressed air, and future uses planned for the next few years. If underestimated, it is possible that the compressor turns out to be inadequate after a short while, if overestimated, then it means that energy and money are wasted.

Buy Energy-Efficient Models  

Since most of the industrial units are operated almost round the clock, expenses on electricity constitute a good proportion of the operating expenses. Therefore there is a need for energy efficiency to be a consideration when selecting a compressor motor. Ask for the kW rating of the unit, and insist on the purchase of only the most efficient compressed air systems that are ENERGY STAR certified for optimum return on your investment within two to three years.

Consider Total Life Costs   

Besides the initial costs of the purchase, consider the ongoing costs of operating the equipment, the extent of maintenance, the frequency of repairs, how often the parts need to be replaced, etc. While a piece of equipment may be cheaply priced, it could very well be constructed shoddily and would therefore require much more maintenance in the long run. There are professional manufacturers of every model who will give precise TCO per model; the data should be used to work out if it is really economical to spend more money initially to save for ten plus years.

Purchase from Reputable Brands  

Air compressors are capital intensive and therefore, acquiring only from well established manufacturers / air compressor distributors (Ingersoll Rand, Atlas Copco, Quincy, Sullivan-Palatek, Sullair, etc. ) are likely to have better efficiency, lower life cycle costs and long warranty periods. Also ensure they have a network of dealers within the region for installations, repairs, technicians, timely supply of parts among other factors. Do not go for cheap brands with big claims or little track record or Islander warranties.

Get Professional Installation

It is not advisable to attempt to install huge industrial compressors on your own if you are not adequately skilled or knowledgeable. Have the ease of mind and hire professionals who have necessary certifications in performing tasks of location planning, assembly, calibration, trial testing and links to piping/outlets as per safety standards only. After that, they educate staff members on safe and effective usage of those specifications.

Don’t Undersize Feeder Circuits 

It is important here to ensure that circuit connections are correctly sized with reference to starting and running currents so as to avoid system failure or even risk of a fire outbreak. Do not use multiple compressors on an undersized circuit as it tends to have a negative impact on the performance of the compressor. It is recommended to hire certified electricians to evaluate the need and connect them to the circuit breakers with the right volts and wire thickness.

Conclusion

By understanding how air compressor capacity is defined and making the right choice, customers will experience minimal cost and reduced time lost due to equipment failure in the course of using the equipment. It is recommendable to seek consultancy from the compressor system specialists especially for large complicated industrial plants. Purchasing the right product initially is cost-efficient because, in the long run, you get returns on your investment through efficiency.