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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... Read more »

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Excess moisture in your compressed air system can cause problems both within the system itself and for the applications that utilize it. Appropriate maintenance and the use of air dryers can remove moisture from your air and extend the life of your system. What Causes Moisture in Compressed Air? Moisture is an inevitable byproduct of compressed air. All air contains a certain amount of water vapor. The volume of water held by the air varies with temperature and pressure; the higher the temperature, the more water air is able to hold. That’s why humidity tends to be higher in warmer... Read more »

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200+ Manufacturers Have Air Leaks Fixed Free Through “Fix-it-Now” Program In Chicagoland, Fluid-Aire Dynamics has been hard at work helping manufacturers save money and energy by fixing compressed air system leaks through ComEd’s Leak Repair Program. Last month, that work was recognized by ComEd. We are proud to have been recognized for the Most Projects Submitted in 2019 at the ComEd Industrial Systems Energy Efficiency Service Provider (EESP) Kick-Off event in February. Raj Raghavan, an Energy Advisor for the ComEd Energy Efficiency Program, says, “Fluid-Aire is a great group of people to work with. No matter who you interact with... Read more »

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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 »

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Have you ever dusted yourself off with compressed air and ended up getting power washed with water instead?! Where did that water come from and does it belong there? As we learned in science class, the air we breathe contains water in a gaseous state. The compressed air industry expresses the amount of water in a system by dewpoint and relative humidity. The warmer the air, the more water the compressed air can hold. This is why we see so much more water in our compressed air on a hot summer day after it has rained. When we compress the... Read more »

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How does moisture effect your CNC machining centers? Does yourcompressed 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 of... Read more »

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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

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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 »

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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 »

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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 »

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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 »

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There is really only one key difference between fixed speed and variable speed drive ; Variable speed drive (VSD) rotary screw air compressors are an increasingly popular choice for companies seeking to reduce energy costs and qualify for energy company incentives. How do you know if a VSD air compressor is right for you? Learn the benefits of VSD, when to use a VSD vs. a fixed speed compressor, and why you may want to consider using both. What is a Variable Speed Drive Air Compressor? A variable speed drive (VSD) controls the frequency supplied to the drive motor on the air... Read more »

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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 »

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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 »

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Air compressor preventative maintenance (PM) is essential for the safe and efficient operation of your compressed air system. But most facility maintenance technicians don’t know all the ins and outs of proper air compressor equipment maintenance. Here’s what building managers and maintenance staff should know—and how you can reduce the burden of compressed air system PMs. Why Air Compressor Maintenance Matters A poorly maintained air compressor will end up costing your company money, both directly and indirectly. Some of these costs include: Higher energy costs due to overloaded filters, blockages, inadequate lubrication, and other problems that cause your air compressor... Read more »

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