Compressed Air Archives

Compressed air uses

Written by Tami Matthews on October 19, 2019. Posted in Air compressors, Compressed Air, Compressed air systems, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

Compressed air is important to many different industries and greatly impacts business. Industries that use compressed air include food and beverage, medical, pharmaceutical, manufacturing, aerospace, amusement parks, HVAC, construction, road and highway work, breweries, energy sectors, dry cleaning, ski resorts, woodworking, automotive, railways, and many others. Without air, many of these industries couldn’t produce safe or satisfying products!

Air – the fourth utility

The popularity of air compressors is largely due to the flexibility of compressed air. Compressed air is so common that it is often considered the fourth utility right after water, electricity, and natural gas. It can be involved in anything and everything because of such a wide range of uses comes to a need for variety.

Different compressor requirements for every business

Not all companies, even within the same industry, have the same needs when it comes to compressed air. Companies need varying sizes and powers. Each business has varying budgets and legal requirements, too. No matter what the horsepower or budget, Elevated Industrial Solutions specializes in providing what you need while reducing energy costs, and effortlessly integrating into your current system.

Why Kaeser Compressors?

If you’re not familiar with Kaeser, the company is considered the gold standard in compressed air. Kaeser has been engineering solutions since 1919, starting with gears for automobiles. They expanded quickly, creating their first compressor in 1948. Since then, the company has grown and expanded to just about every continent. Today, they’ve innovated add-ons and features, such as the Kaeser Sigma Control 2 which enables you to control your entire compressed air system.

Although they may be more expensive in upfront costs, no doubt you’ll save money over the life of your compressor. Typically, these compressors require less significant maintenance to keep them up and running. They’re more efficient, too. It’s why Kaeser machines are considered to have great ROI (return on investment).

Elevated can help get you the right compressor

Elevated Industrial Solutions has supplied Michigan and Ohio with compressed air systems for more than 34 years. Our sales engineers, technicians, and installation experts are certified. We’ll never sell you more power than you need and will always look for ways to save you money on energy. Our goal is to make you more efficient and effective.

Plus, we can provide industrial supplies, coating and finishing equipment, and precision tools for your industrial, construction, or manufacturing company.

dont get fooled get the real deal - kaeser

Don’t get fooled – go with the real deal (Kaeser and dealer expertise)

Written by Kaeser Compressors on February 4, 2015. Posted in Automotive, Compressed Air, Industrial, Industrial, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

We’ve all been there. I would wager we’ve all done it. When it comes time to get an oil change or replace our windshield wipers, we want to go for the store brand, not the genuine replacement part. It’s cheaper. Isn’t it? It’s just as good. Right?

I’m not an automotive expert, so I’m not going to debate the merits of saving a few bucks on windshield wipers. However, I would like to point out a few key points to consider when you are purchasing replacement parts for your compressor.

Efficiency

No doubt a key factor, when you were purchasing your compressor, is energy efficiency. You did the research, looked at the CAGI datasheets, and compared performance. That compressor was tested as it was packaged by the manufacturer using the manufacturer’s original parts. This may not seem like a big deal, but keep in mind that every component inside the compressor is crucial to its performance, thus its efficiency. For example, intake filters are susceptible to pressure drop; every 2 psi in pressure drop costs 1% of compressor horsepower in efficiency. If you use an aftermarket filter, you might not get the compressor efficiency you are expecting. And that will cost you money—possibly more than you are saving by going with the cheaper part.

Service intervals

Your unit came with a manual that has a host of useful information from the manufacturer—including recommended service intervals. Those intervals are based on the extensive testing done using their original parts included in the machine, not aftermarket ones. You might be ok using the same guidelines, but there is really no way of knowing simply because the manufacturer didn’t test the unit using those aftermarket parts.

Quality

The material compatibility of the aftermarket parts has not been tested with the compressor. Neither has the durability of those aftermarket parts. Quite often we see new issues develop, for example, higher oil carryover from using a sub-par replacement separator element. Other issues such as higher pressure losses after shorter operating periods, compromised machine safety, and air quality not being met are also common. Further, depending on what your manufacturer’s stated warranty is, using aftermarket parts can void it.

To be fair, there are quality aftermarket parts manufacturers out there—their products, however, have just not been thoroughly tested with the compressor, which can lead to problems and concerns. Be careful and be aware. Your best bet is to contact the compressor manufacturer and go with their genuine replacement parts. I didn’t really save any money by getting the store-brand windshield wipers. They lasted maybe four months. The genuine replacement part wipers that are now on my car have lasted more than a year and they only cost a few dollars more. They also work better.

I guess that goes to show that you get what you pay for. Pay now or pay way more later!

Get your compressors ready after the holidays

Written by Kaeser Compressors on January 8, 2015. Posted in Compressed Air, Compressed Air, General, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

The holidays are over and for many plants that mean seasonal shutdowns or lower production demands are also a thing of the past. While everyone is gearing up to start this year with gusto, don’t forget to stop and take a breath before bringing your equipment back online.

coming back from winter holidays presents some challenges to air compressors

Here is a short list of points to check on your compressors to make sure they are ready to get back to work. The first three tips are important to check after any shutdown period. The last two apply to compressors that have been offline for an extended period of time.

Check the temp

Check the ambient temperature. If it is below 40°F, the compressor will need either a cabinet or ambient heater in order to start safely. If it’s too cold, the lubricant will not circulate through the unit properly, causing a cold start. Cold starts can cause unnecessary wear and tear on the motor and airend and sometimes even catastrophic failure.

Grease the motor bearings

Make sure the motor bearings are properly greased. Some compressors have external lubrication points which makes re-greasing easy. Otherwise, be sure to check the grease zerks (fittings) on the rear and front of the motor.

Valve off and start slowly

If you have any filtration in your compressed air system, valve off the compressors before starting and then slowly open the valve to the system. This will prevent the filter from being blasted with high-velocity air—which can cause damage to the filter elements and can also cause contaminants to enter the compressed air stream. To prevent this from happening in the future, consider installing an air main charging valve.

Prime with oil

If you have equipment that has been offline for an extended period of time (6-8 months), the airend will need to be primed with oil. This is typically done by removing the inlet valve and pouring oil directly into the airend. Check your service manual and consult the compressor manufacturer for specifics on the type and amount of oil to use. Don’t forget that during periods of shut down it is good practice to run the unit once a week for a least 30 minutes. This will help prevent corrosion—in particular on the airend and in the fluid separator tank.

Additional help for your compressors

For variable speed drive compressors that have been sitting for more than 12 months, they will need to have their capacitors re-formed before start-up to prevent severe damage to the electrical panel. Contact the manufacturer for help.

7 deadly sins of compressed air

Written by Kaeser Compressors on December 2, 2014. Posted in Compressed Air, Compressed Air, Compressed Air, General, Industrial, Manufacturing. Leave a Comment

When putting together a compressed air system, temptation is all around you. You want the best system, but having the best doesn’t mean grabbing whatever looks good. Build a system that meets your needs, not your wants. Focusing on your system’s needs and avoiding these seven deadly sins will keep you from needing to confess when your utility bill arrives.

1. Lust

Don’t lust after a variable-frequency drive compressor. Many utilities offer rebates for a VFD, but they are not always the best solution. Sellers often make blanket claims of huge savings, but if your compressor will run fully loaded more than 75% of the time, savings are very limited. Keep in mind that they are more expensive and have drive losses which need to be considered. If you have an application where the load varies between 40-80% of compressor capacity, then a VFD makes sense. Do the math before you buy one to make sure your system will benefit from using this technology.

2. Gluttony

Don’t be a glutton with your air treatment. Dry air sounds great, but there is such a thing as overkill. And overkill is expensive. This is especially true for larger, industrial compressed air systems supplying multiple processes. Take a hard look at your system and determine what level of filtration and dew point each segment needs. If you need a desiccant dryer for only part of your process, then size it for that part only. You’ll not only save by buying smaller capacity equipment, but also on pressure drop, air loss, and energy.

3. Greed

Don’t be greedy for air by oversizing your system. Bigger is not always better. Oversizing means you are paying for more energy than you need to. In some cases, if the compressor is too large for the demand, it may not come up to temperature, causing excess condensation. The machine will cycle on and off, which puts unnecessary wear and tear on the motor, valves, and seals. Figure out the amount of air you need for your system and select a compressor that will meet it. And, if you determine your load varies widely, consider using a VFD.

4. Sloth

Don’t be lazy attending to leaks. Leaks occur and reoccur and need to be continually monitored and repaired. The US Department of Energy estimates that as much as half of all compressed air is wasted, with an average of 25% lost to leaks. I’ve seen annual leak losses range from $3,000 for smaller systems and up to $600,000 for larger ones. Check for leaks and repair them once you find them. You’ll be putting money back on your bottom line every time you do.

5. Wrath

Beware the wrath of poorly controlled compressors. If you notice pressure spikes, disruptions in your air supply, or compressors cycling on and off, that means the compressors need to be controlled with a master system controller. A master controller monitors system demand and selects the right combination of units to meet it in the most efficient way possible. Don’t leave them to their own devices. Keep them under control.

6. Envy

Don’t be envious of other plants with the newest technology simply because it is new. Choose what is best for your application. Some installations are using the latest in remote monitoring and taking advantage of cloud-based solutions. Good for them. Don’t let the latest and greatest distract you from your system’s needs. Stay focused on what is right for your installation.

7. Pride

Don’t be so proud of your system that you fail to monitor its changing needs. You’ve worked hard to put together an efficient system and in the process, you’ve saved a lot of money in energy costs. Don’t rest on your laurels. A good way to stay on top of your system is by doing an annual compressed air audit. This will help you see trends and react to any changes that might be happening in your demand profile.

When putting together a compressed air system, temptation is all around you. You want the best system, but having the best doesn’t mean grabbing whatever looks good. Build a system that meets your needs, not your wants. Focusing on your system’s needs and avoiding these seven deadly sins will keep you from needing to confess when your utility bill arrives.

Embrace humility regarding your compressed air system

At Elevated Industrial Solutions, we have the expertise to help your air compressors or compressed air system reach peak efficiency. With air audits, maintenance, and a host of other tools, we can evaluate how to improve your system or whether it needs improvement.