Compressed Air Archives

Buying an air compressor – what you need to know

Written by Tami Matthews on June 2, 2020. Posted in Compressed Air, Compressed air systems, General, Industrial, Industrial supplies, Manufacturing, Metalworking, Woodworking. Leave a Comment

Buying an air compressor is complicated and requires some expert knowledge. Not everyone involved in the buying process is a facility or plan engineer/manager, either. So we put together a guide to help you or help explain to others in your company what to look for.

Compressed air terms

To help you familiarize yourself with the terms concerning air compressors, turn to this shortlist of definitions that will be helpful for your next air compressor purchase:

Pounds per Square Inch (PSI) — the measurement of air pressure and force that is delivered by an air compressor. Higher numbers mean that a larger volume of air can be compressed in the tank.
Pounds per Square Inch Gauge (PSIG) — the measurement of air pressure and force that is delivered by an air compressor relative to our atmospheric pressure at sea level, which is 14.7 PSI. Most gauges are calibrated to read 0 at sea level so the 14.7 psi of the earth’s atmosphere is not measured.
Actual Cubic Feet per Minute (ACFM) — the actual volume of air pumped in one minute from a compressor running at its rated operating conditions of speed, pressure, and temperatures.
Standard Cubic Feet per Minute (SCFM) — the representation of the volume of air pumped in one minute at 60 degrees Fahrenheit (15.6 degrees Celsius). Some air compressors will be rated with SCFM to provide a more accurate working rating since air contracts and expands at different temperatures.
Horsepower (HP) — the measurement of power the motor produces. The higher the number, the more work the air compressor can do to deliver a greater PSI and ACFM.
Brake horsepower —Horsepower delivered to the output shaft of a motor or engine, or the horsepower required at the compressor shaft to perform work.
Indicated horsepower —The horsepower is calculated from compressor indicator diagrams. The term applies only to displacement-type compressors.
Intercooler — part of the air compressor that cools air between compression stages.
Aftercooler — a heat exchanger used for cooling air discharged from a compressor. The resulting condensation may be removed by a moisture separator following the aftercooler.
Pneumatic tools — tools that operate by air pressure.
Positive displacement compressors —Compressors in which successive volumes of air or gas are confined within a closed space and space is mechanically reduced, resulting in compression. These may be reciprocating or rotating.

Air compressor options

Here are three general categories that air compressors fall into.

Consumer-grade air compressors. These models are perfect for simple jobs like inflating tires, sporting goods, and other inflatables. Most have the power to operate small-load air tools.

Professional-grade air compressors. These are designed to power more demanding tools, making them perfect for contractors, woodworking shops as well as small garages.

Commercial/Industrial-grade air compressors. Redesigned to provide a steady flow of compressed air for extended periods of time. These compressors are built with high-quality components and come with additional features that use advanced technology to improve performance, energy efficiency and reliability.

Determine the work your compressor will do

Here are some questions that you will want to answer before buying an air compressor.

Where will you be using your air compressor?

The first thing you will need to choose is between performance and portability. The reason is that the wheeled design has less power than most stationary units. So If you’d like to roll it to different areas in your shop or building or transport it to different locations, you might need to sacrifice some performance to achieve it. Nevertheless, it is very important to make sure that the performance of the air compressor you choose covers your needs. If your compressor is too small, the air compressor will run more frequently, use more electricity and wear out quickly.

Is there a dependable electrical supply?

Another very important thing you need to take into consideration is your electrical supply. Because the fluctuations in power delivered can cause severe damage to your air compressor. Most manufacturers will also deem this as improper use and will void any warranty on the compressor. If that’s your case, you might want to choose a unit that works with gas instead.

What tools do you want to use with your compressor?

Determine what tools you will be using with your air compressor at one time. All air tools have an average CFM rating, so look at it to ensure you get an air compressor that will provide you with the power you need.

What is the maximum operating pressure (PSI) you’ll require?

To answer this question, you will need to check the specifications of the air tools you will be using, for example, if a blowgun with 2.5 CFM at 90 PSI is your tool with the highest requirements then you would want to get an air compressor with a minimum 90PSI rating.

Knowing this also will help you choose between a single-stage or two-stage design among piston models. Two-stage models will have a higher PSI than single-stage compressors since the second compression of air will increase the PSI.

What is the maximum air volume (CFM) you’ll require?

Pneumatic tools require different levels of air volume to operate properly. So it’s vital to be sure that your air compressor can give you the CFM needed, especially if you have more than one airline from your air compressor. In those cases be sure to get your minimum CFM rating from all tools that could be used at one time, so you don’t underestimate your airpower needs.

We recommend increasing the CFM total you get from the highest-rated tool (or the total number of highly-rated tools that could be used at the same time) by 30 to 50 percent to ensure that you have adequate performance under the most demanding applications you may encounter.

For example, if you had two airlines and your highly rated tools that could run at the same time are an impact wrench with a CFM of 7 and a spray gun with a CFM of 6 then you’d want to look for an air compressor that can deliver in the range of 16-20 CFM

7cfm+6cfm=13cfm

13×1.3 (30%)=16.9

13×1.5(50%)=19.5

What size tank will you need?

As a general recommendation, we would suggest you get the largest, practical-size tank you can afford within your CFM and PSI requirements.

The reason we recommend this is that it can affect the operation of some tools, especially the ones that require air continuously, like sanders and grinders.

Also if the tank is too small, it will strain the motor of your air compressor, because it will have to run more often than it was designed for, to keep your tank full, shortening the life of the compressor. The longer the air compressor can go without switching on again, the less strain on the motor and the better return you’ll get on your investment.

Finally, if your tank is too small for your needs, the compressed air might be used before it has the time to cool down. As a result, condensation will build up in your airlines damaging your tools as well as your compressor. Larger tanks and other features such as intercoolers and aftercoolers allow the air to be cooled before flowing through the airline.

What horsepower (HP) is needed for the motor of your air compressor?

The HP of the air compressor doesn’t affect the performance of the tools or the air delivery directly, but it’s an important factor to take into consideration. The HP is a rating for the motor or engine’s power. The engine creates the compressed air and delivers it into the tank. The higher the HP, the more efficiently the air tank will be filled, which reduces the recovery time.

Air compressor features explained

After answering all these questions probably you have a good idea of what air compressor to buy. Nevertheless, some of the features might still be unclear, making it hard to decide. Below are some of the common air compressor features with a brief explanation.

Belt drive or direct drive. The motor of most rotary screw-type air compressors can be either belt-driven or direct-driven. Direct drive models have the motor directly connected to the crankshaft of the compressor. They can operate at lower temperatures and high-energy efficiency but are usually more expensive, difficult to maintain, and noisier.

Belt-drive compressors have a belt that connects the motor to the air compressor pump with pulleys. They offer greater flexibility to adjust the airflow and pressure as needed. They are also less expensive to purchase and are easier to install and maintain. These models are not ideal for severe temperatures or harsh conditions.

Auto start/stop or continuous speed or dual control. These features deal with the operation of compressed air production. Auto start/stop means the air compressor is set with a pressure switch that automatically turns the motor on when the air is needed and turns it off when the tank is full. Continuous speed is for air compressors that constantly run and will adjust the airflow as the demand requires. Dual control offers the option to set the air compressor to either run in auto start/stop mode or continuous mode as needed.

Vertical or horizontal tanks. Vertical tanks take up less space, which could be a deciding factor for you. The biggest benefit of horizontal tanks is portability.

ASME parts. These parts or components have met the standards and codes set by the American Society of Mechanical Engineers.

Low oil protection. The air compressor is equipped with technology to shut itself down in the event of low oil levels, preventing downtime and expensive repairs due to low fluid levels.

Ball-valve tank drain allows safe and easy draining with a simple quarter turn in the tank for frequent removal of any moisture.

Need more help choosing the right air compressor?

We have sales engineers who can provide recommendations on the right compressor to use based on your circumstances. Understanding your budget and timing to bring in a compressor (especially with lead-time delays) can help, too.

Contact Elevated with any other questions you have about buying an air compressor or locate one of our sales and service reps near you.

Monthly air compressor maintenance

Written by Tami Matthews on February 6, 2020. Posted in Air compressors, Automotive, Compressed Air, General, Industrial. Leave a Comment

Maximize compressor efficiency and lifespan by performing monthly preventive maintenance checks. Or hire a certified service technician to handle your compressed air system to ensure you’re getting expert support.

Follow these 6 monthly steps to ensure your Kaeser compressed air system is running efficiently and properly.

1) Check belt tension

To make sure that your air compressor will function properly, check that the tension of the belt drives is optimal to avoid slipping and premature wear of the drive belts and pulleys.

2) Check the cooling oil level

Most air compressors require a certain amount of oil circulating throughout their system. If this amount is not enough, the internal temperature will rise, which will ultimately lead to the compressor overheating and shutting down. If the problem is not solved promptly, it will result in premature wear.

3) Cooler: check the filter mat

The filter mat helps to keep the cooler clean. If the filter mats are clogged, inadequate cooling of the components could result

4) Control cabinet: check the filter mat

A filter mat is placed behind every ventilation grille. Filter mats protect the control cabinet from the ingress of dirt. If the filter mats are clogged, clean or replace the filter mats.

5) Check the condensate drain

Condensation is an inevitable result of air compression. If the condensed liquid is not adequately drained off at all collection points, it will cause corrosion that will damage the compressed air system.

6) Log all maintenance tasks completed

Documenting all the maintenance work will determine if there is any deviation from the OEM’s recommendation. Remember: That only qualified and authorized personnel should be allowed to perform any maintenance task.

Elevated can help with preventive maintenance

Some compressors come from Elevated with a warranty, guaranteeing we’ll service your compressor. For others, you’ll need to ensure you get on a maintenance schedule. Luckily, Elevated makes it easy. When we sell you a compressor, we provide a maintenance schedule based on the make and model as well as the environment and runtime expected or experienced on your compressor. Plus, our team is certified.

Compressor life cycle cost

Written by Tami Matthews on January 27, 2020. Posted in Air compressors, Compressed Air, Compressed air systems. Leave a Comment

Many factors go into the total cost of investing in a compressed air system. Focusing on just the upfront expenses can hurt your company and cost thousands. For example, energy usage alone can outpace the initial price of the compressor in just a couple of years. These factors make up the overall return on investment (ROI) you’re getting when you think of budget costs.

Here are 4 categories to consider when thinking about the life cycle cost of your compressed air system. It’s especially important to consider as the purchase price is only a fraction of the overall cost — over the years — of your machine.

Purchase price

The initial cost of the compressor can vary greatly. Larger manufacturers may use more expensive equipment to reduce reliability issues and increase productivity. Getting the right machine for your environment is crucial – the durability needed, correct horsepower, etc. (The right vendor will never give you more horsepower than needed.)

Compressor parts and service

Getting a brand that’s known for its reliability is a good start. Some brands are definitely more durable than others. These high-performance machines will cost you less, generally, in parts and service.

But service is an important component, especially getting service in a timely manner. Vendors who are available 24/7, 365 days a year that you can rely on when you need them is crucial. You also want certified technicians who are experienced with your compressor, no matter the brand.

The most expensive issue comes from not servicing your compressor at all. It can cause additional wear and tear on your compressor, increasing operating costs (more parts and service). Worse, it can also potentially shut down your facility, halting production. (We’ve seen this happen!)

Energy costs

It’s no secret that industrial air compressors consume a lot of energy. Many modern compressors are highly efficient and will produce much more air for less money. Kaeser, for example, is known for its high performance. Considering energy is the largest cost, this should be a primary focus when purchasing a new compressed air system.

The right vendor will help you find ways to save money, even if you’re purchasing the most expensive brand.

Additional factors

Additional factors include load/unload cycle time, air leak losses, non-production operation, system pressure set points, and individual components that can make a difference in the cost of your compressor’s operation.

Elevated is there for the lifecycle of your compressor

Elevated has certified technicians available 24/7. Parts are in stock. We offer ultrasonic leak detections, air audits, and scheduled maintenance to save you time and money. In other words, we work to eliminate any downtime. Let us make recommendations on your compressed air system or service needed.

Custom-engineered air compressor solutions

Written by Tami Matthews on January 3, 2020. Posted in Compressed Air, Compressed Air, Compressed air systems. Leave a Comment

Custom-engineered solutions are designed for the most demanding installations and harshest of environments. These complete systems are exceptionally reliable, simple to maintain, and have superior energy efficiency, no matter what the installation limitations may be. Space, weather, and accessibility constraints are eliminated with reduced construction, installation, and operating costs.

These custom-engineered solutions are completely turnkey, reducing onsite planning and installation costs, which save you time since there is no need to build a new compressor room or add onto an existing building. They can even be built to be moved from one site to another. Every component is selected with your installation and location in mind.

Plan and design

Whether you call it planning, designing, or even engineering, we start by partnering with you to determine what you need. We’ll ask a series of questions based on your environment to start spec-ing out the best solutions, including your enclosure or skid configuration. We’ll use that information to begin designing the necessary wiring, and power distribution to a single service connection.

Then, we add thermostatically controlled inlet louvers and exhaust ducting as well as supplemental heating as needed for reliable operation nearly anywhere on the planet. Based on your system requirement, we select the right compressors to meet your pressure and flow needs and mount them to the floor with vibration isolators. Air treatment comes next and includes dryers, filters, receiver tanks, and condensate management. We have options for every grade of compressed air quality from the shop to the instrument to oil-free and even breathing air.

Prepare and deliver

After that, we run piping throughout the package to a single connection that ties the entire system directly to your plant. To efficiently control air output and remotely monitor the system for preventative maintenance, planning, and troubleshooting we install Kaeser’s Sigma Air Manager 4.0. (SAM 4.0) also constantly measures and reports energy consumption. Your system will give you complete access for maintenance and repair.

Finally, we deliver your customized air system to you.

Don’t worry about site preparation, just provide a level surface capable of holding the weight of the system. Whether you need compressed air, blower, or vacuum systems give us your spec and we’ll deliver a complete system faster than you can budget, plan, permit, and build a new building or expand an existing facility.

Elevate works to design these custom-engineered solutions

We have experts who help design these custom-engineered solutions, working with Kaeser to get them to your location whether you’re in South Carolina, Ohio, or Michigan. We also provide services (such as preventive maintenance and emergency repairs) as well as traditional compressed air systems. When it comes to compressed air systems, we do it all.

common compressed air maintenance mistakes

7 common air compressor maintenance mistakes

Written by Tami Matthews on December 2, 2019. Posted in Air compressors, Compressed Air, Compressed Air, Featured. Leave a Comment

When it comes to your business, compressed air represents a significant operating cost. Between the compressor, system, installation, and maintenance, your compressed air system can cost tens of thousands or hundreds of thousands of dollars (depending on the size of your facility). But did you know you may be wasting money through common air compressor maintenance mistakes?

Mistake 1: not purchasing a cost-efficient, easy-to-maintain machine

A lot of factors go into the entire cost of compressed air systems, not just the initial price of the compressor. These factors include the lifespan of the compressor, maintenance costs, frequency of maintenance, and energy usage. These costs will far outweigh the price of the compressor, so it’s important to purchase a high-quality and reliable compressor that is easy to maintain.

Mistake 2: air leaks

Air leaks, whether you’re ignoring it or don’t know it, can cost you thousands. Your compressed air system will work overtime to keep up with demand, increasing wear and tear on your compressor as well as energy costs. Ensure you do not have air leaks by performing routine leak audits.

Mistake 3: infrequent inspections

Your compressor receives scheduled maintenance, but maintenance may not cover everything that happens to your compressor. Wear and tear, dirt, and broader maintenance needs may be causing your compressor to run longer to meet air demand. (Your expert service technicians should be recommending how often your compressor needs maintenance and other audits based on your environment and runtime.)

By performing inspections, variables such as temperature, humidity, dust, and wear and tear on your compressor will be managed which will improve efficiency.

Mistake 4: compressed air pipe

Certain piping materials can promote contamination, leaks, and pressure drops. Regardless of the material, the pipe will eventually need to be cleaned of debris and eventually replaced. Failure to clear this debris can lead to inefficiencies and additional issues for air tools and your compressor. SmartPipe+ by Kaeser does not promote contamination which increases the lifespan of the piping and system.

Mistake 5: air demand

It is very common for companies to overestimate or underestimate air demand. Often times this underestimation leads to needing new equipment. By performing a demand analysis you’ll able to identify the exact amount of air you need even across different departments. If your equipment has already been purchased and is not meeting demand, oftentimes you do not need to replace your compressor. Upgrading tank size and reducing inefficiencies with an air management system will provide additional air at a lower cost, helping you meet the required demand.

Mistake 6: training staff

At some facilities, machine operators are less experienced and less knowledgeable of the compressed air system than management. Providing additional training to operators will help provide more air at a lower price, help spot maintenance issues before they arise and reduce stress on your compressor.

Mistake 7: data collection

Being able to spot issues early will prevent issues from becoming worse, downtime repairing the machine, and time spent figuring out what went wrong in the first place. Collecting data on your compressed air system with help identify future issues. Once again having well-trained staff and collecting data will help identify potential issues before they get worse.

Elevated doesn’t make maintenance mistakes

Getting Elevated service means you won’t have these common mistakes. Instead, our team of experts will do everything necessary to keep your compressed air system running at peak efficiency. Our team is certified and can train your personnel as well as deliver just about any data you need. Plus, we work with energy companies to save you money. For an air demand analysis (ADA), ultrasonic leak audit, SmartPipe+ information, or maintenance, contact our team. We’d love to help!