Air leaks are very common in compressed air systems. The key is to know how to detect and fix them as the cost of even a tiny leak adds up to a large expense if left unattended. How common are compressed air leaks? Compressed air leaks are widespread in all applications. Not only are they common, but they are time-consuming to find and fix. In the average manufacturing operation, 20-30% of the total energy consumption is compressed air. On average, 30% of that expense is due to compressed air leakage. How costly are compressed air leaks? Here are 2 examples… Read more »

Many times, when planning a new compressed air system, there is a debate about whether or not to buy a receiver tank. Even operators of established systems sometimes wonder… what is the function of air receiver tank? We collected several questions that we often get about this vital part for an efficient compressed air system. What is the primary role of a compressed air storage tank? Compressed air storage Steady air signal to the compressor controls Secondary heat exchanger The main purpose of air receiver tanks is to provide air capacity to meet high-demand events that last for short periods… Read more »

How does a backup compressor help my operation? In the typical manufacturing operation, compressed air is mission-critical. If it goes down, you may as well turn off the lights and send everyone home. Besides losing production time when your compressor goes down, usually the product that was being produced at that moment is ruined too. Take a food manufacturer for example. If production suddenly stops, not only do they lose the hours of production that they are down, but whatever is currently in their production line is most likely spoiled because it may not be baked, or mixed, or put… Read more »

Refrigerated Air Dryers As a refrigerated air dryer chills compressed air to 33–40°F, water vapor condenses into a liquid. Then it is expelled from the system via a water trap and automatic drain. The cool, dry air is reheated to room temperature, exits the dryer, and into the production lines. This helps reduce condensation in the compressed air piping system. There are two types of refrigerated dryers – cycling and non-cycling. Non-Cycling Air DryersNon-Cycling air dryers allow the refrigeration circuit to run continuously. The temperature is controlled by the use of a hot gas bypass valve and the cycling action… Read more »

Ambient air always contains some level of moisture. When you compress air, the moisture will condense and can cause problems if it isn’t addressed. When an oily water mixture, (the byproduct of condensation) makes its way through the air lines and to points-of-use, it can cause many problems. Blasting and painting processes are affected, along with pneumatic tools, CNC machining centers, robotics, and many other applications. When a compressor draws in air, it is compressed about 8 times the normal atmospheric pressure in order to achieve 100 PSI. Moisture that is present as a vapor in the air begins to… Read more »

Air compressors range from large-scale industrial machines to small portable units. Purchasing the right machine for your need requires knowing the basics of how an industrial air compressor works and understanding your application. Whether you want to use an air compressor to power air tools or to apply a smooth paint coating, you must know how the different technologies available will affect your application. Types of Air Compressor Systems When you plan to purchase an industrial air compressor, your first task is deciding the type of the air compressor that you have to buy. In terms of design and principle… Read more »

  The importance of understanding relative humidity to dew point when working with compressed air systems. How many of you consider the relationship between relative humidity to dew point and the effect it can have on your compressed air systems? We spoke with several customers, and people who work in the industry, and we have discovered that many don’t understand how important it is to know both terms when talking about compressed air dryness. Knowing the relative humidity percentage and dew point temperature helps you ensure your compressed air systems are functioning properly and can help save you from costly… Read more »

Why Do You Need One? Compressed air produced by any oil flooded compressor has contaminates. After the air is cooled by the heat exchanger and/or the dryer, the contaminants including water and oil condense and become a liquid. To properly dispose of this liquid, the oil needs to be removed from the water so that the water can be reintroduced to the municipal water system. This can be achieved through the use of air compressor oil separator. If you do not use an oil/water separator and you dispose of the liquid from your dryer by dumping it into your usual… Read more »

Temperature plays a key role in how your air compressor will perform on a day-to-day basis. Your compressor may be outside all year long or in a warehouse where temperatures easily fluctuate. No matter the environment, knowing the ideal temperatures your air compressor can function in, is very important. When determining the optimal temperature range for your air compressor’s environment, you should look at it from two different viewpoints: Mechanical StandpointBetween 50 and 85 degrees Fahrenheit is the ideal operating temperature. This isn’t too cold or too hot, thus avoiding freezing and overheating. Air Density StandpointColder air is actually better… Read more »

How to know the right amount of compressed air your facility needs. There are many ways and methods that can be used in determining how much compressed air is needed to supply your facility, and believe it when we tell you – Getting a properly sized compressed air system is very important. Why do we say that? Under-sizing an air compressor will cause the system not to work. Both over-sizing and under-sizing your equipment can lead to large budget constraints that management never likes to deal with. Over-sizing your equipment can be costly too due to long-term maintenance and higher… Read more »

How does a backup compressor help my business? Let’s use a manufacturing business as a perfect example; compressed air is vital for operations, and if it goes down, you may as well turn off the lights and count your losses. You will soon find out that besides losing production uptime when the compressor is down, it may also spoil the current product that is in your lineup when you go down. For example, if a food manufacturer goes down, not only do they lose the hours of production that they are down, but whatever is currently in their production line… Read more »