Compressed Air Archives

Kaeser’s Sigma Air Manager 4.0

Written by Tami Matthews on April 23, 2022. Posted in Air compressors, Compressed Air, Compressed Air. Leave a Comment

We’ve heard it before – you’re doing everything you can to save money on compressed air energy, but it’s not working. You’re purchasing energy-efficient compressed air system equipment yet your energy costs aren’t as low as they could be or maybe even should be. Compressed air systems are comprised of a lot of different equipment which can idle when they aren’t needed. Even though your equipment is energy-efficient your compressor, blower, dryer, etc. are all reacting to the needed output demanded.

There’s another piece of equipment that could help.

Introducing the Kaeser Sigma Air Manager 4.0 (aka SAM 4.0)

The award-winning Kaeser Sigma Air Manager 4.0 (SAM 4.0) efficiently gives you more air for less money while increasing productivity. SAM 4.0 has adaptive controls, predictive maintenance, data storage, and analysis – all while maintaining a reliable, consistent, and efficient supply of compressed air. It’s a device that works with your entire system, but also provides a display to enable you to understand how it’s controlling your system.

Management of your entire compressed air system

Kaeser’s Sigma Air Manager 4.0 ties in all of your compressed air system equipment including compressors, blowers, and vacuums into a secure Sigma network. That control into one device enables you to manage your entire facility or industrial plant.

Because it controls the entire system, you’ll have steady pressure, energy savings, and efficient use of air!

Messaging and maintenance

In addition, built into SAM 4.0 is a predictive maintenance reminder and messaging abilities. The device communicates exactly what maintenance needs to be performed and when you should do it. No more mind-reading! That functionality obviously makes it easier for you to schedule maintenance, prepare your workforce for maintenance, and get service technicians on the calendar. It also makes it easier for your compressed air service technicians to keep you up and running, eliminating downtime.

These built-in features ensure you never miss preventative maintenance, maximize efficiency, and maximize the life of your compressor and equipment.

Easy-to-use touchscreen technology

SAM 4.0 features a user-friendly 12-inch color touchscreen, which means it’s fairly easy to use. The home screen shows real-time operating status, power consumption, pressure history, flow, and error messages. This data can be accessed anytime and anywhere, giving total control to the facility manager.

Ready to use SAM 4.0?

Are you ready to get steady pressure, receive communication about issues and reports on analytics, and save money on energy? Our Michigan, South Carolina, northern Ohio (near Toledo), and southwestern Ohio (near Cincinnati and Dayton) teams can install SAM and get you up and running. We’ll conduct training to ensure you understand what you’re seeing, too. Plus, we can maintain your system and be there if SAM communicates any issues – 24 x 7, 365 days a year.

Signs your air compressor needs service

Written by Tami Matthews on January 21, 2022. Posted in Air compressors, Compressed Air, Compressed Air, Compressed air systems. Leave a Comment

There are lots of signs your air compressor needs service — it’s dripping oil, it’s smoking, it’s noisier than usual, etc. Those are obvious. But there are times when your compressor needs service and it’s not as obvious. Here are a few:

Run-time or calendar

signs your air compressor needs service infographic

Consider run-time as part of your preventive maintenance. We recommend annually or every 2,000 hours, whichever comes first.

Weather

Extreme weather can cause big problems to your air compressor, either when it’s too hot or too cold. One tip for hot weather: try power washing your air compressor.

Plant conditions

Dirty, dusty, and other poor environmental conditions can cause issues with your air compressor. For these environments, we recommend more frequent service.

Higher costs and energy

Another good time to get service or an audit is when you notice higher-than-expected energy bills. You may even think you need a new compressor when you need to determine what’s wrong with your current setup. Easy ways to determine include an air demand analysis, leak audit, or other analysis to investigate the culprit.

Contact us for service

At Elevated Industrial Solutions, we provide maintenance and audits before your air compressor becomes an emergency. Our technicians have experience taking care of every major brand of compressor. And we service locations across the tri-state area – Ohio, Kentucky, and Indiana – as well as South Carolina.

We even have 24/7 service for emergencies. (We just hope it doesn’t come to that!)

This is why you don’t use PVC

Written by Kaeser Compressors on October 5, 2021. Posted in Air compressors, Automotive, Compressed Air, Compressed Air, Compressed Air, Countertop, Distribution, Featured, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

PVC is lightweight, inexpensive, and easy to purchase at any local building supply store, making it all the more attractive when it comes to selecting piping materials for a compressed air system.

Using PVC, however, has its risks and in certain areas, it may not be code compliant. It also carries a static charge which can lead to spontaneous combustion in certain dust-filled environments, it’s subject to bursting (yes bursting), and the adhesives used in installation are not compatible with all types of compressor oils. Despite the safety issues, many small shops and even some larger plants continue to use it.

A couple of years back we were installing a compressor at a medical device manufacturer in Colorado, and we noted the plant’s wide use of PVC piping. I asked the shop manager (who was three weeks from retiring) whether they’d had any issues with PVC cracking or bursting under pressure. He said yes, many times. “Pieces fly across the room.” He would just replace them. “No one’s been hurt so far…”

In a room with 4 huge, expensive injection molding machines and many employees, he saw no need to change. Different strokes, I guess.

Here are two more examples:

1. The remains from a 2” PVC pipe burst at a manufacturing plant in Texas. Thankfully no injuries, but some unscheduled changing of underwear.

2. In a small customer paint shop in Texas, a large section of PVC pipe burst during normal operation. Again, there were no injuries.

If you have PVC pipe in your shop or factory, make sure it’s pressure rated and regularly check it for signs of cracking.

For those of you considering using PVC pipe, I urge you not to—it’s really not worth the risk.

preventive maintenance and audits for air compressors

Why frequent air compressor maintenance and audits

Written by Tami Matthews on December 11, 2020. Posted in Automotive, Compressed Air, Compressed Air, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

Air compressors are the lifeblood of many facilities – keeping your business going. They help you deliver your company’s products on time and on budget. Compressor Station Audits can assist too, in ensuring you’re using your equipment to the best of its ability.

Together, preventive maintenance and audits (air compressor service), keep a facility running.

Preventive maintenance

Did you know that you should be having your air compressors serviced at least once a year or for every 2,000 – 3, 000 hours of service? In addition, extreme weather conditions – caused during winter and summer – are great times to get your air compressor serviced.

At a minimum, compressors need a variety of routine maintenance:

Fittings and belts tightened and inspected
Oil changed
Filters changed
General inspections
Cleaning of all coolers and drains
Collection of oil samples for testing
Recording amp draw
Recording voltage
Checking for abnormal vibrations and noise
Injection and discharge oil temp
Lubricating drive motor bearings

If you’re behind on your maintenance or considering an audit, here are a few good reasons to invest in maintenance … before it’s too late.

Save money on replacing a compressor as well as get more efficiency

It probably goes without explaining that preventive maintenance can save money in the long term. A new air compressor, being replaced after not maintaining your old one, is costly.

What often happens, though, are air compressors being used inefficiently due to lack of maintenance. One auto shop couldn’t keep up with customer demand due to delayed maintenance.

Prevent shutting down your plant or handling costly repairs

When air compressors aren’t serviced regularly, they become more apt to break down or quit completely. Of course, when an air compressor breaks down, the facility could come to a halt. Shutting down operations costs your company time and money, even potentially impacting your customers.

But it goes beyond stopping or slowing operations. The labor costs for emergency repairs can be expensive, too. Although Compressed Air Technologies handles emergencies, including middle-of-the-night repairs, we don’t recommend customers wait for that scenario.

Prevent injured workers and fines

You also probably know that if compressors are mishandled or misused, they can be dangerous, causing serious issues. Those issues can vary wildly from hearing damage to killing a worker.

If a worker does become injured on the job, including his hearing damaged, they can file a worker’s compensation claim and potentially even sue your company. One law firm indicates their median settlement for hearing loss is around $55,000.

OSHA has standards for how air compressors are used in facilities, even where they’re used. Violations of those OSHA standards can be expensive; OSHA fines are up to $70,000 per violation.

Audits

Audits are an important part of the equation for keeping your facility running. Typically, managers ask for an audit before adding compressors. Audits provide a snapshot of overall controls, get an idea of peak usage and capacity, and more.

Audits are used for the following:

Weaknesses in your existing system, including leakage
Inefficiency in the compressors you’re using, including too much horsepower
Providing guidance on reconfiguring your current system for better airflow

Save money from buying another compressor

By receiving an audit, you can identify whether you really need an additional compressor. Compressed Air Technologies technicians often see managers ready to buy a new compressor when one isn’t necessary. Many times, air compressors aren’t being fully utilized. Technicians and engineers can help you reconfigure your setup to ensure maximum efficiency.

Not purchasing an additional – and unnecessary – air compressor could save thousands of dollars. For example, Kaeser has a case study on one audit, where they identified a furniture company that was wasting $600,000.

Save money on energy and energy consumption

Audits can point out leaks to reduce them as well as ensure energy is being used efficiently. Even if energy consumption isn’t an overall goal of your company (such as those seeking ISO certifications or meeting tight environmental standards), it can save money. After all, the more compressors you’re using, the more energy you’re consuming.

One Kaeser case study indicates one company saved (with a utility rebate) $78,031 in the first year alone. Audits are a fraction of that cost.

Audits + maintenance together

Audits + Maintenance – it’s the formula for running an efficient facility. Together they can save you money. They keep workers safe, prevent unnecessary fines and lawsuits, and keep your plant moving.

At Elevated Industrial Solutions, we enable you to meet customer demands on time and on budget. Our technicians have a combined 60+ years of experience. And although we handle late-night emergencies, we provide – and can help you schedule – regular maintenance to prevent catastrophes at your facilities.

Air compressors for the manufacturing industry

Written by Tami Matthews on August 4, 2020. Posted in Aerospace & defense, Compressed Air, Manufacturing. Leave a Comment

Compressed air plays an important role in the manufacturing industry. It powers your facility to make everything from car parts to consumer goods. So, getting the right compressor is important.

Among the manufacturing companies needing compressed air for industrial processes include:

Primary product industries (suppliers of semi-finished raw materials to manufacturers)
Heavy goods manufacturers
Consumer goods processing and packaging
Transportation
Construction
Aerospace
Automotive
Cement production

Here are some key considerations to incorporate into the decision-making process:

Power

Choose an air compressor that will drive tools and power your machines and processes with no hassles. Get a vendor that can provide recommendations to get just the right power (not too much or too little). Also, some vendors – such as Elevated Industrial Solutions – can provide ideas on how to save energy, working with energy companies to get you rebates.

Efficiency

The more power an air compressor requires, the higher the fuel cost, which is a significant operating expense. Ask for ideas on how to make your compressed air system more efficient for the manufacturing processes you’re running.

Maintenance requirements

Some compressors have higher maintenance costs than others. In addition, your manufacturing environment (such as a cement plant) could require more maintenance than others.

Choose an air compressor that requires as little maintenance as possible to ensure that your operations run smoothly. Also, ensure you’re working with an expert team certified in your compressor and who are available 24 x 7. Having people available, in case the worst happens (such as a shutdown) is imperative.

Warranty

Choose an air compressor manufacturer that stands behind their product with a strong warranty.

The right vendor: Elevated

When looking into compressed air systems, it’s important to have a compressed air audit to determine your specific needs. Our specialists can also help you check if there are tasks that can be done with less expensive options for a high-performing compressed air system. We have 24 x 7 repair service available to get your facility up and running during emergencies. And we warranty our compressors so you have peace of mind.