As manufacturers, you're constantly looking for ways to save money in order to grow our bottom line. This will allow you to grow your business. It is recommended that instead of taking a lot of resources out of one or two departments, manufacturers can grow their bottom line through several small cost cutting initiatives that add up to save large amounts of money.
First of all, what is a VSD (Variable Speed Drive) rotary screw compressor and how is it different than a fixed speed rotary screw compressor?
How does moisture effect your CNC machining centers? Does your compressed air system have the proper dryers or filtration needed to keep your machinery operating at peak efficiency? Solenoid valve and tool change-out problems on your CNC machines? If you are experiencing problems with solenoid valves and tool change-outs on your CNC machining centers, the problem could be that you are not supplying the CNC with clean dry compressed air to prevent rust and oil contamination. As you would know, when a tool change-out is being performed both the shank and the inside of the tool holder receive a blast... Read more »
Is Your Air Compressor Overheating? Do you experience excessive downtime due to your air compressors shutting down on high temperature? Does downtime cost your company money? Here are a few reasons your compressor may be shutting down with high temperature alarms; Dirty or clogged coolers (air/oil) Low on oil Clogged Oil Filter(‘s) and, or Air/Oil Separator(‘s) Faulty Thermal Valve Faulty HAT(High Airend Temperature) sensor Excessive ambient temperatures If compressor is ventilated, ducting may be undersized or need a booster fan Compressor oil may be varnishing causing excessive friction in the pump
This week’s discussion addresses what seems to be an unknown to most users of compressed air. Many calls come in from customers who say their compressor system no longer keeps up with plant demand. Of course, this could be due to many factors such as added production equipment, air leaks in the equipment and/or distribution piping, or the need of maintenance to the air compressor itself. To troubleshoot your plant pressure issues, we recommend beginning with the source of your compressed air. Is the compressor delivering its rated Actual Cubic Feet per Minute (ACFM)? ACFM is the air delivery rating... Read more »
Now is the time to verify your equipment is in top running condition. Compressors generate a tremendous amount of heat on their own. Everything possible needs to be done to help them keep their cool. Your mission today is to take action to avoid any unnecessary shutdowns, motor failures, excessive condensate in your plant air, or other issues. Downtime is very costly. There are a few key areas to look at in regards to getting your equipment ready for the higher ambient temperatures. Below are a few bullet points of the most common things to look for. Safety First –... Read more »
If you are shopping for a new air compressor, you might be overwhelmed by the different types and options. The first and most important choice you will make is whether to buy a rotary or a reciprocating compressor. Many people don’t know the difference between them, so let’s look at these two types. Reciprocating air compressors compress the air with pistons that move up and down inside the cylinders. Rotary screw air compressors have two rotors that turn in opposite directions. The air is trapped between thus causing compression to occur. Their manner of compressing air is not the only... Read more »
Have you ever been down for what seems like “no reason whatsoever”? Even if you haven’t, ask yourself if you have you been doing regular service on your compressed air system. Servicing your compressed air system is important because it helps prevent downtime and having decreased productivity for reasons that could have been avoided. Air compressor maintenance is simple, necessary, and inexpensive in comparison to the downtime and repairs needed on a machine and/or system that hasn’t been maintained. So how often should your air compressor(s), dryer(s), and oil/water separator(s) (air compressor oil separator) be serviced and what does that... Read more »
We all know what it is to go from room to room at home turning off all the lights that the kids left on. We are sensitive about the thermostat setting at home during the winter, keeping it lowered at night or when not home for an extended period. We fix the drippy kitchen faucet, or the toilet that runs continually. These are examples of cost cutting measures to keep our utility bills more affordable. But what about your compressed air system at your place of business? Compressed air is your fourth, and most expensive, utility. Minimally, it costs you electricity to... Read more »
1. Loop type distribution system – In most cases a loop type distribution system is beneficial. Loop type compressed air systems allow the air to flow in any direction to get to the demand in the path of least resistance. Typically you can multiply the capacity of straight line piping by 1.5 for loop type compressed air distribution systems. For example: If a 2” pipe is rated for 500 CFM at 125 PSI that same length of pipe in a loop system would be rated for 750 CFM at 125 PSI. 2. Feed the loop type piping from a dry... Read more »
I bet as a business owner, or even as a great employee, you are always thinking of ways to improve your company’s efficiency. Compressed air is used in many different industries all over the world for a variety of critical operations. Read on to learn 11 tips for reducing air consumption and energy costs. Remember, compressed air is not only your 4th utility, but also your most expensive utility. 1. Eliminate pressure drop: A few of the major contributors to pressure drop are inadequate pipe sizes, undersized and dirty filtration, excessive filtration, inadequate storage, and air compressor maintenance issues. 2. Install low... Read more »
Changing the oil on your rotary screw air compressor is important for the life of the machine and can avoid large repair costs. On top of checking it regularly to ensure it’s topped off, you should change it at regular intervals. The length of this interval depends on the type of oil being used in your machine. Rotary Screw Air Compressor or Rotary Vane Air Compressor** Standard Oil every 8000 hrs or 12 months Food Grade Oil every 2000 hrs or 3 months If you don’t change your oil as above a few things can happen to your compressor: Buildup... Read more »
What are the main differences between refrigerated and desiccant air dryers? Refrigerated Air Dryers A refrigerated air dryer chills the compressed air to 33 – 40 degrees Fahrenheit at which water vapor is condensed into a liquid and is then expelled from the system via a water-trap and automatic drain. The cool dry air then is typically re-heated to around room temperature before exiting the dryer and going to your production lines. This helps reduce condensation on the compressed air piping. There are two types of refrigerated dryers; cycling and non-cycling. Non-Cycling Air Dryers: Non-Cycling air dryers allow the refrigeration circuit... Read more »
You’ve made a sizable investment into your air compressor, so you’ll want to get the most life from it that is possible. Here are some simple steps that will help you achieve years of trouble-free operation. Follow instructions – It may seem obvious, but reading the manual for your air compressor is a small time investment with big payoff. You’ll learn the maintenance schedule as well as operating guidelines for your compressor. With this information, you can extend the life of your equipment and minimize downtime. Check oil levels daily – For compressors that use oil, check oil before every use.... Read more »
In the Food & Beverage Industry Calling all Food or Beverage Manufacturing Companies! 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 food or beverage manufacturing plant and believe it when we tell you – Getting a properly sized compressed air system is very important. Why do we say that? Undersizing an air compressor will cause the compressed air system not to work. Both oversizing and undersizing compressors can lead to large budget constraints... 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 »
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 »
Updated Dec 9, 2016 Your air compressor is vital for keeping production in operation and key equipment running, so handling preventative maintenance in a timely manner is important. By scheduling regular air compressor maintenance with a reliable local service company, you prevent lost productivity and downtime that comes with not doing regular upkeep of your compressed air system and equipment. Check out our preventative maintenance plans! There are also checks that you can do yourself to help save you service costs and prevent the need for emergency repair. Daily: Check oil levels Check oil pressure Inspect for air and oil... Read more »