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Author Archives: Compressed Air Systems

1. 3 Things to Look for When Choosing a VMAC

   May 21, 2018 3:38 pm Comments Off on 3 Things to Look for When Choosing a VMAC

   While offering a range of unique benefits, rotary screw compressors also come with a steep price tag. Though larger systems may be cost-effective even with a rotary compressor, the cost of these high-tech instruments can be a serious hindrance when working with smaller systems such as vehicle mounted air compressors (VMACs), which are often housed in trucks.

   Traditional reciprocating piston compressors and rotary screw compressors are both viable options for vehicle mounted applications. But these models have unique, distinct features, often making it difficult to choose between the two.

   Below are three key considerations to keep in mind when selecting the best type of VMAC for your specific application.

   1. Size and Weight of the VMAC

   Fuel cost is a key consideration when budgeting for VMACs, and a lighter compressor can offer significant cost saving advantages. In fact, a 200-lb reduction in weight can result in fuel cost savings of 4%. This also allows the application to be free of stringent DOT regulations.

   Rotary screw compressors are clearly the best option in this regard, as they are lighter than piston compressors of the same rated capacity. Rotary screw models are time-tested, and can be expected to operate reliably for long periods of time. They also allow for consistent air delivery, which means receiver tanks are unnecessary in most applications.

   2. Continuous Air Power

   In any type of job, an interruption in supply will result in increased downtime and higher costs. Therefore, it’s essential that the compressor chosen can provide a continuous air supply, which will allow jobs to be completed at the fastest rate possible — thereby enhancing customer satisfaction and upping the number of projects that can be finished in a given time frame.

   In this regard, rotary compressors are superior to traditional reciprocating piston compressors. For example, the RAPTAIR-G30 model offered by Compressed Air Systems provides continuous 30 cfm air flow, as well as a 100% duty-cycle rating. This translates to continuous operation and a continuous compressed air supply; the air tools can be employed continuously, and no time is wasted due to lack of compressed air availability.

   3. Cost

   Naturally, cost is a critical consideration when choosing one type of compressed air system over another. Cost is arguably the most important factor in any type of commercial project. However, it’s essential to maintain a balance between quality performance and cost investment.

   For example, traditional rotary compressors, though reliable and time-tested, come at a very high price. As an alternative, the VMAC G30 is the most affordable gas driven rotary screw air compressor available. It offers the power and performance of a rotary screw air compressor, but at a more affordable cost,  close to the price point of a reciprocating air compressor.

   Learn More

   Compressed Air Systems has been an expert in compressed air technology since 1963, and we’re proud to offer our RAPTAIR-G30 gas-driven rotary compressor to clients across a range of different industries. This unique compressor is nearly half the size and weight of other compressors with similar ratings, and supplies reliable, uninterrupted air flow. RAPTAIR-G30 compressors come with a lifetime warranty.

   To discuss whether the RAPTAIR-G30 is right for your unique application and learn more about air compressors for trucks, contact a product specialist today. Or, to further explore the features and benefits of both rotary screw air compressors and the RAPTAIR-G3, download our comprehensive VMAC guide.

2. Avoiding Moisture Content Issues in Compressed Air Systems

   April 27, 2018 6:13 pm Comments Off on Avoiding Moisture Content Issues in Compressed Air Systems

   All types of compressed air systems contain some quantity of water vapor, putting solenoid valves, air motors, and entire systems at risk. If this air moisture is not carefully maintained, overall system efficiency can suffer greatly, affecting performance, production time, and the bottom line.

   Compressed air systems of any variety operate best with the cleanest, driest air possible. So, to ensure that these systems work effectively, moisture must be closely monitored; unwanted moisture is inherently damaging to the processes at hand, and can be detrimental to the products being manufactured as well. If you’re noticing an obvious warning sign in the system, it’s probably too late; you’ll likely need to replace the essential parts in order to return operations to peak performance levels.

   Common Warning Signs of Moisture Content Issues

   While moisture is often considered an unavoidable problem in compressed air systems, measures can be taken to prevent it before it becomes a serious issue. Compressed air systems face a long list of risks as moisture increases, with compromised output and operational problems such as:

   • Loss of lubrication, leading to increased wear and tear on moving parts and unnecessary system strain
   • The creation and buildup of rust, corrosion, and other damaging contaminants
   • Scaling and orifice clogging that can lead to operational failure in pneumatic controls
   • Failing parts, which can cause an immediate risk of shutdown, production losses, and unnecessary downtime
   • Frozen control lines and cold-weather malfunctions
   • Unexpected air leaks, which can result in loss of pressure and capacity while creating an opportunity for additional moisture and contaminants to infiltrate the system
   • Bacterial growth, which can compromise the quality of compressed air systems used in the food and medical sectors, disrupting production and making products unfit for use
   • Leaking water from open valves or sticking valves, requiring part replacement

   Effective Maintenance Measures for Combatting Moisture Problems

   

   No facility wants to get caught up in a cycle of constant moisture-related part replacement. A few simple maintenance measures can make all the difference for the health of your compressed air system. Access to clean, dry compressed air will always be a major asset to operations, allowing for enhanced performance and lower operating costs while ensuring minimal part damage.

   Below are some key maintenance tips to keep in mind to ensure optimal system performance and reliability.

   • Plant managers can implement dew point monitors as an early identifier of moisture problems.
   • Teams can work to design consistent, effective maintenance and review schedules, eliminating the need for heavy spending on major part replacement.
   • Specialty equipment can prepare managers for effective system maintenance; air dryers, inline filters, and drain systems are all excellent tools for avoiding and managing moisture buildup.
   • Adding a valve to dry air tanks makes daily moisture monitoring simple and straightforward; plant managers can check regularly to ensure operations are running properly. And if the drain in the dry air tank comes on, staff will be alerted immediately that there is an issue.
   • Master controllers allow for thorough system monitoring by tracking system temperatures, dew point, and flow for essential health and preventative maintenance needs.
   • Inline air filters provide key protection for compressed air systems; routine filter checks and replacements ensure that extra moisture and system contaminants can be easily removed.

   Working With Compressed Air Systems, Inc.

   The team of compressed air technicians at Compressed Air Systems (CAS) works closely with all of our clients to ensure that they find the ideal moisture management solution for their unique application. We’ll work to identify the right type of air dryer for your system based on performance goals, specific uses, and particular environment and operating conditions.

   And our walkthrough service, free for Florida customers, features on-site testing and system sampling to help

   

   ensure the best fit. We can also work with you to map maintenance needs, creating a personalized set of review checklists andschedules to protect your system and guarantee peak performance.

   To learn more about moisture management and compressed air system optimization, download our Guide to Moisture Content in Compressed Air, or contact our specialists today.

3. Why Air Receiver Tanks Are Essential for Your Compressed Air System

   March 15, 2018 1:34 pm Comments Off on Why Air Receiver Tanks Are Essential for Your Compressed Air System

   Air receiver tanks, also called compressed air tanks or simply air receivers, are crucial elements of compressed air systems. Air receiver tanks have two main purposes: to serve as short-term storage units during temporary demand spikes, and to help systems perform more efficiently overall.

   To think of it another way, air receiver tanks perform much like batteries: By utilizing stored energy, a lower-horsepower machine can be employed to complete a larger task. Because of the massive amount of pressure these tanks are often under — not to mention their vital importance in compressed air systems — they must be both durable and strong.

   There are two kinds of air receivers: wet and dry. Wet receivers are placed immediately after the compressor.

   In addition to serving as storage tanks, these receivers also help reduce moisture. Dry receivers, on the other hand, are placed after the air dryer or other air preparation equipment, and can minimize drops in the air pressure of a compressor system.

   1. Integrating Air Receiver Tanks Into Your Facility

   Typically, an air receiver tank is sized at six to 10 times the flow rate of the compressed air system. By law, tanks must have a pressure relief valve and a pressure gauge. The relief valve is typically set to 10% higher than the working pressure of the system.

   Also, it’s crucial to have either a manual drain or an automatic drain on the receiver tank so water can be easily removed from the system.

   The removal of moisture is especially important in cold weather, as moisture can accumulate and reenter the flow of outgoing air. Plus, if the temperature falls below 32 °F, the condensate line will freeze, potentially damaging the pipe.

   Moisture can also cause rust and scale to form on the inside of the tank, both of which can be carried in the outgoing air and cause premature blockages of filters. A coalescing filter and air dryer usually are placed downstream of the receiver tank.

   Air compressors — typically smaller-range ones — may be “tank-mounted” on top of an air receiver. Space-constrained plants usually opt for this arrangement. However, this won’t work for most larger compressors, as they’re much more top-heavy and would pose a danger.

   2. The Importance of Air Receiver Tanks

   In addition to storing energy and optimizing the efficiency of compressed air systems, air receiver tanks perform several other important duties.

   First, they help regulate compressor controls to prevent short cycling and over pressurization. Failing to install a receiver — or using one that’s too small — will cause a compressor to rapid cycle, which can cause a range of different issues.

   Next, an air receiver tank also serves as a second heat exchanger. As air passes through it, the air temperature drops about 10° below what it was after cooling via the first heat exchanger.

   Air receiver tanks also precipitate some of the moisture and oil carryover that may be present in the compressed air as it leaves the compressor or is carried over from the after-cooler.

   And finally, these versatile tanks help reduce the dew point and temperature spikes that can occur after regeneration.

   Learn More

   Air receiver tanks serve a critical role in compressed air systems across a range of different industries. In fact, not using one can be downright dangerous.

   Need help selecting an air receiver tank for your specific application needs? Reach out to the team at Compressed Air Systems (CAS) today to request a quote and discuss your options with an expert.

4. How to Save Money and Optimize Your Compressed Air Systems Using Master Controllers

   February 15, 2018 2:49 pm Comments Off on How to Save Money and Optimize Your Compressed Air Systems Using Master Controllers

   The Real Cost of Compressed Air

   As compressed air is used in a huge range of industrial operations, it is critical to understand the cost implications that come with its use and even misuse. The energy created through the use of compressed air is commonly used in many different ways from manufacturing uses to oil-free sensitive breathing air.

   It can also be used for a range of tasks as simple as spraying dust off a product with an air gun, or as complicated as helping assist a robotic arm in production. In fact, compressed air is often considered the fourth utility in industrial operations, after electricity, water, and natural gas.

   (more…)

5. Nitrogen Generators for the Food Industry

   November 17, 2017 1:47 am Comments Off on Nitrogen Generators for the Food Industry

   Pure nitrogen plays a critical role in ensuring optimal consumer safety for all types of perishable foods. Used for both the transportation and storage of food products, nitrogen allows for efficient, economical preservation, locking in freshness and flavor while safeguarding human health.

   Nitrogen is the dominate gas in atmospheric air, but food freshness can be affected by even small amounts of oxygen, which allow harmful microbes, such as bacteria, to flourish. Therefore, nitrogen-rich environments with no more than 2% oxygen by volume are ideal for the processing, packaging, and storing of food products. In fact, nitrogen generation is employed in almost every step of food processing  operations.

   (more…)

6. Understanding High-Pressure Air Compressors

   July 20, 2017 3:40 am Comments Off on Understanding High-Pressure Air Compressors

   Used in a wide range of industries, high-pressure air compressor solutions are used in applications that require consistently high pressure and additional pounds per square inch (psi) — generally around 650 psi or higher — to complete certain tasks. Compressor boosters are also available to serve as add-ons for existing systems.

   At Compressed Air Systems, we often field questions about the different types of high-pressure systems and their specific properties and benefits. Below, we’ve addressed some of the most frequently asked questions.

   (more…)

7. The Environmental Impact of Condensate Management

   May 25, 2017 2:31 pm Comments Off on The Environmental Impact of Condensate Management

   As with most industrial processes, the creation of compressed air can produce undesirable byproducts that must be managed to keep processes running smoothly. One of the most prevalent consequences of using compressed air systems is the creation of condensate, a mixture of moisture and oil.

   Compressed air systems are regularly flooded with oil; a 100-Hp compressor passes an average of 10 gallons of oil per year. Just 1 gallon of oil, however, can contaminate about a million gallons of water.

   (more…)

8. How To Optimize Your Complete Compressed Air System

   April 19, 2017 2:22 am Comments Off on How To Optimize Your Complete Compressed Air System

   A complete air system is not just in the mechanical room where the compressor station is, but it is the complete system including the distribution of piping, hoses, fittings, regulators and other components that are needed for each application.

   Maintaining and optimizing your complete system starts in the compressor room with routine maintenance, and includes the modernization of your controls.  A complete system analysis serves to identify energy efficiencies and pressure control, and helps to pinpoint potential areas for savings.

   (more…)

9. Compressed Air Systems for Dental Office Applications

   February 21, 2017 3:13 am Comments Off on Compressed Air Systems for Dental Office Applications

   Dental air compressors are integral parts of any functioning dental office. Unfortunately, they are not often discussed or even thought about until it’s time for a dental health professional to purchase one.

   Operating repeatedly throughout each and every day, dental air compressors need to be durable. Because they’re used to treat patients, there exists the potential to negatively impact health, so the air that these compressors produce must be especially clean. In dental office settings, they must also operate quietly using standard 220/110 volt power sources.

   If you’re shopping for a dental air compressor, educating yourself about their unique characteristics will help to select a high quality dental air compressor that best suits your needs.

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10. Compressed Air Systems for Breweries and Distilleries

    December 6, 2016 2:08 am Comments Off on Compressed Air Systems for Breweries and Distilleries

    Compressed air systems are an essential part of a variety of applications, including the production of beer, wine, and liquor as compressed air is vital in both the brewing and distilling process.

    When searching for compressed air components and selecting a partner, breweries and distilleries will need to take into account not only what works for where they are now but where they want to grow in the future.

    At Compressed Air Systems, we understand that our partners want to spend their time crafting the perfect beverages instead of worrying about planning for and servicing their equipment. Below is a list of a few of the components that Compressed Air Systems regularly supplies to our brewing and distilling partners nationwide.

    (more…)

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