Businesses everywhere can often benefit by installing a professional and reliable air compressor. These types of air filtration and drying products are used in a variety of facilities, workshops, factories, warehouses, and other commercial and industrial premises, helping staff to get work done productively and effectively. Ensuring air quality and safety is vital for manufacturing and engineering facilities that are bound by strict compliance regulations.
With so many types of compressed air dryers and compression systems on the market, with the KAESER range of refrigerant and desiccant dryers proving popular, some facilities and operations managers may be at a crossroads when it comes to deciding the right one for their operation. When the time comes to decide on the right air compressor, there are several key factors to consider regarding system size, airflow, pressure, and more, so finding a reliable solution for your facility can be easier said than done.
What’s more, it’s important to know what to look for in an air compression system, as certain types will be better suited for specific workplaces. Therefore, choosing one that doesn’t meet your needs can often hamper productivity and cause valuable resources to go to waste.
Thankfully, with this short guide, you can be more prepared as you evaluate this key investment for your facility. Read on to find out what to look for in an air compressor, factors to consider, and steps to help make the decision much easier.
Industry Applications and Trends
Firstly, it’s important to understand whether your premises can benefit by having an air compressor installation. Air compressors have become increasingly popular in a wide range of commercial and industrial settings in recent years. Air compressors are pneumatic devices that can power a variety of tools, working by putting atmospheric air under high pressure. This ‘compresses’ the air and converts it to kinetic energy which is stored in an air tank.
Some common applications include everyday items such as fridge-freezers, air conditioning systems and vehicle engines. However, in commercial settings, compressed air dryers may be used in several other lesser-known ways:
- Car body shops and manufacturing plants: These systems often power tyre inflation guns, paint spraying, and other production processes.
- Construction and building maintenance: Compressed air can be used in operating nail guns, caulking tools, and sandblasting.
- Food processing and packaging: Air compressors can be used to vacuum-seal products to minimise oxygen content and prevent early contamination.
- Agriculture: To power water pumps effectively and consistently for livestock.
- Energy: Compressed air systems can power gas turbines by pressurising collected air and combusting it with fuel to generate power.
- Pharmaceutical and medical facilities: Certain air-gapped medical products, equipment and machinery rely on compressed air to minimise the risk of infection.
Factor 1: Sustainability
In recent years, there has been a growing emphasis on energy efficiency and sustainability in the processes of power generation, including batteries, electric vehicles and now also air compression. Investing in variable speed drive (VSD) technology can make air compressors more energy-efficient, which means that the speed can be adjusted in response to changes in air demand, allowing users to optimise their efficiency and minimise emissions.
Many other air compressors now have features such as advanced monitoring that allow you to keep track of its performance and energy consumption while controlling its settings remotely.
Understandably, many eco-conscious facilities managers may feel reassured knowing that there are ways to take advantage of air compression systems without presenting an unreasonable cost to the environment. Be sure to factor in a system’s eco-rating and reliability to ensure it aligns with your short- and long-term sustainability goals.
Factor 2: Air Demand
Compressed airflow is typically measured in cubic feet per minute (CFM), while air pressure is usually measured in pounds per square inch (PSI). Determine whether a prospective air compressor can meet the airflow and pressure needs of your premises, bearing in mind any future or imminent growth or expansion plans that may increase (or decrease) your air demand over time.
Ensure that your compressor’s capacity and maximum pressure match or exceed your air demand requirements. Pressure can always be adjusted to make the compressor run at below maximum levels, but if it doesn’t quite measure up to the standard you need, you may need to seek a more powerful model.
Be cautious of your compressor’s duty cycle (i.e. how often it will need to run continuously). Different air compressor models will have different cycles and may mandate minimum periods of downtime and a maximum amount of consistent usage before overheating. Determine how often you’d need a compressor to run continuously before selecting your model.
Factor 3: Compressor Type
There are two main types of compressors: piston air compressors and rotary screw air compressors.
Piston compressors (also known as reciprocating compressors) are economical and relatively inexpensive, ideal for smaller applications where intermittent air demand would be sufficient. Rotary screw compressors, on the other hand, are better suited for larger applications that require continuous air supplies, offering stability and reliable distribution of compressed air.
Some compressors utilise oil as a form of lubrication, whereas others don’t. While this may seem like a fairly irrelevant deciding factor, it can influence long-term energy efficiency. For clarity, oil-free compressors are ideal where air purity and quality are vital (i.e. the food, pharmaceutical and medical industries), as these don’t use any oil and therefore pose no risk of spillages or emissions into the air. Conversely, oil-lubricated compressors do pose these aforementioned risks, but can often run for a longer time uninterrupted.
Other Factors to Consider
- Air compressors can be noisy, particularly if they’re located near quiet workspaces or customer areas. Bear the noise level in mind when choosing your model.
- Make sure that you measure the available space in your facility and choose a compressor that can be accommodated without posing a safety hazard.
- Price isn’t everything: look beyond the bottom line. Consider the total cost of ownership, including the initial purchase price, the ongoing energy and maintenance costs, and the frequency of filter or spare part replacements in your budget.
- Review the manufacturer’s recommended compressed air dryer maintenance schedule and warranty coverage to offer peace of mind.
The Road Ahead
The compressor manufacturing market, while having undergone a recent dip, is projected to increase rapidly in the next five years. Therefore, there is little to suggest that compressed air systems are things of the past.
Before investing in a commercial air compressor, it can help drastically to consult a reputable and experienced supplier who can provide the expertise and support you need. A supplier can conduct a thorough, means-tested assessment of a system and make tailored recommendations for the product that will meet your facility’s requirements. They will be able to offer a selection of quality, trusted options to choose from, offering guidance on maintenance, installation, and troubleshooting, as well as repair and genuine spare part access.
Working with the right air compressor partner will help you confidently make an informed decision that will meet your commercial needs while enhancing your overall operational efficiency.
