Posted by Compressed Air Systems on | Comments Off on Top Tips for Energy-Saving Air Compressor Maintenance
Globally, the air compressor market is quickly growing due to the versatility and cost-effectiveness of air compressor units. Between 2020 and 2028, the market is expected to grow at a rate (CAGR) of 3.4% annually. However, despite the wide adoption of air compressors, many businesses don’t prioritize air compressor maintenance, resulting in increased expenses due to costly repairs or replacements and the associated downtime. Air compressor maintenance offers you many benefits, such as time savings, safety enhancements, and reduced production costs due to less energy consumption. See our guide to inline clean air treatment here.
Top 5 Energy Saving Tips
Regardless of your specific industry or application, a well-maintained air compressor plays a vital part in reducing energy consumption. Here are five top tips you can implement to increase the energy savings from your air compressor:
Cost Saving Advice: Hoses, Fittings, and Waste
Check your fittings regularly, ensuring they create a tight seal. Loose fittings are a significant cause of leaks in air compressor units. If the fittings seem corroded or worn out, you should repair or replace them immediately. Consider inspecting hoses since they act as the system’s key connection points, and any damage to the hose could disrupt the entire system. Hoses usually get damaged during cold weather or bent, resulting in corrosion or cracks. Additionally, drain your unit’s receiver tank to avoid suboptimal operation due to a lack of storage capacity.
Apply Proper Controls to Multiple Compressor Units
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Proper controls maintain steady system pressure and ensure that only the required compressor units are brought online. This eliminates the inappropriate use of compressed air and ensures each unit is operating at peak efficiency. The controls are also helpful in turning off compressor units that are not needed or not being used.
Ensure Piping & Storage are Properly Sized
The problem with most systems is the lack of adequate storage and piping. When sizing piping, it should optimize the transfer of compressed air at the desired flow and pressure to the point of use. Having wider piping from two to three inches can minimize the pressure to around 50%. On the other hand, reducing the distance traveled by air can lower pressure by about 30%-40%. Having the wrong storage size can result in issues with production or increased costs due to wasted energy.
Change Your Air Filters Regularly
Air filters should be inspected monthly and replaced regularly. Drops in pressure as little as two psi can cost about 1% in compressor horsepower efficiency. Regular inspection and replacement maintain air quality and reduce the chance of pressure dropping. There are several point-of-use and air-line filters in a typical system, which should also be maintained regularly.
Reduce the Operating Pressure to the Lowest Possible Setting
A common rule for most compressors indicates that every 2-psi reduction in system operating pressure can result in 1% in compressor energy-saving efficiency. Continuously adjust the pressure setting to reach the lowest possible setting without compromising performance. Additionally, centralized systems using multiple compressors can be set to run using a central controller. Turning down the pressure on your compressor even 10 PSIG is a 5% savings in electrical costs.
Contact Compressed Air Systems for More Advice
Maintaining your air compressor is essential to ensure daily operations and equipment continue running without interruption. At Compressed Air Systems, we are proudly celebrating nearly 60 years of delivering superior equipment design and engineering, custom turnkey installations, compressed air leak detection and elimination, air compressor rentals and services, and more. We have partnered with Kaeser to create a long and productive business partnership as a proud supplier of Kaeser air compressors. Get in touch with us today for more information about our services.
Posted by Compressed Air Systems on | Comments Off on Blower and Vacuum Applications
High-volume blowers and vacuum pumps are vital for moving air in industrial settings. Choosing the right compressed air blowers and vacuum pumps can benefit any pneumatic system and save your business money. Learn more about blowers and vacuum pumps, common applications, and products from Compressed Air Systems that can serve you.
About Blower and Vacuum Pumps
Many manufacturing plants require compressed air blowers and vacuum pumps for basic operations. At Compressed Air Systems, we can provide precision compressor solutions that fit your facility’s needs. We work with trusted manufacturers like Kaeser Compressors to provide reliable, high-quality products, components, and assemblies for commercial and industrial facilities.
Our selection of standard and custom products includes:
Positive displacement blowers: These blowers can deliver a constant high volume of gas through their outlet port.
Radial vacuum pumps: These pumps can deliver controlled volumes of air (typically at high volumes) when systems require air at small differential pressure levels. They can precisely remove air and gas from a fixed area, such as to clean or seal containers.
Rotary claw pumps: Using positive displacement, the non-contacting claws in this system rotate to pull air in and pump it out at controlled volumes and pressure differentials.
Rotary lobe blowers: These blowers use centrifugal force to deliver pressurized air with as little vibration as possible.
Rotary screw: Rotary screw compressors use positive displacement to compress air between two rotors and reduce the size of the chamber. The rotary screws pressurize the gas to the desired level and power pneumatic operations.
Rotary vane pump: A rotary vane pump uses positive displacement to rotate air within a cavity and pull air from a given area.
Blower and Vacuum Pump Applications
Our blowers and vacuum pump systems can remove or supply gases in different volumes, pressures, and directions. Some of the most common applications for blowers and vacuum pumps are:
Air supply for aeration or pneumatic conveying
Bottle filling
Critical instrument air supply
Cutters
Dairy processing and milking
Dryers
Evacuation
Evisceration
Filling and closing machines
Filtration
Humidification
Manufacturing plant vacuums
Modified atmosphere packaging (MAP)
Packaging
Preserving cooked food
Process gas stream
Sterilization
Working With Compressed Air Systems
Because high-volume blowers and vacuum pumps come in many varieties, it can be challenging to know which one is the best fit for your application. At Compressed Air Systems, our team of experts can help you determine the right systems for your industrial or commercial operation. Contact us today to learn more about our products and services.
Posted by Compressed Air Systems on | Comments Off on 5 Benefits of Regularly Changing Compressed Air Filter Elements
Compressed air is critical to an extensive range of industrial and manufacturing processes, including fuel combustion applications, pneumatic tools, filtration systems, metalworking, chemical and petrochemical processing, injection molding, and many others. To ensure optimal air movement and prevent the risk of contamination by particulate matter, compressor systems are typically fitted with a filtration system. These systems require regular maintenance, and compressed air filter elements must be replaced periodically to keep the system operating safely and efficiently.
Why Should I Change My Compressed Air Filter Element?
Compressed air filtration systems typically incorporate a coalescing filter, a dry particulate filter element, or a combination of both. Coalescing filters pull oil and water droplets from the air, while dry particulate filters trap particulate matter such as dust particles and microbes. Both methods require the use of a removable filter element, usually in the form of a cartridge. Due to the harsh conditions typical in an industrial compressed air filtration system, a filter element must be able to withstand:
Broad pressure fluctuations
Extreme temperatures
Varying air speeds
Corrosive chemicals
Extreme humidity variation
Over time, these conditions cause degradation of the filter element, damaging its ability to properly remove contaminants. To ensure optimum performance, filter media must be replaced regularly.
Benefits of Regularly Changing Filter Elements
Every air filter element has a finite service life, and the manufacturer will typically recommend a specific time frame within which to change the filter to guarantee optimal air quality. Violation of your filter manufacturer’s recommendations can result in several problems, including:
Production inefficiency and damage to system components
Poor product quality
Increased downtime and operational overhead
Unhealthy work environment, which can result in employee injury, illness, absence, and legal claims
Consumer safety risks due to product and process contamination
While changing your compressed air filter elements may seem a minor concern, regularly replacing your filters offers numerous benefits, including:
Safer Equipment Operation
Regularly changing your filters ensures that equipment, personnel, and processes downstream from your filtration element are protected from unwanted contaminants. This will keep your employees from being exposed to unsafe conditions due to poor air quality, overheating equipment, or system malfunctions.
Reduced Operational Costs
When you change your filter elements regularly, you reduce your risk for system problems that can result in inefficiency, costly repairs, and downtime. Without appropriate filter maintenance, your compressor system has to work harder to provide adequate airflow. This causes excess wear on the compressor and high energy usage, which increases overall operational costs and decreases the service life of the compressor.
Increased Productivity and Profitability
Changing your filters regularly allows you to increase your facility’s productivity and profitability. With filtered, unobstructed airflow, your system will operate with a greater degree of efficiency.
Protection of Adsorption Dryer Beds
Using a fresh filter allows adsorption dryer beds in desiccant systems to operate with the highest degree of efficiency. With less oil and solid particulate matter in the compressed air flow over the beds, they can operate with a greater degree of effectiveness.
Peace of Mind
When you change the filter element on your compressed air system, you can rest assured that your system is operating with the highest degree of safety and efficiency. Your system will operate more smoothly, and your employees will enjoy a safer, cleaner work environment.
Quality Air Compressor Filter Elements by Compressed Air Systems
To ensure that your air compressor system is in optimal operating condition, it is critical that you perform regular filter element changes. At Compressed Air Systems, we have more than 40 years of experience helping customers find the right compressed air filter elements for use in nearly every industry. Our knowledgeable professionals are available to help you find the best air compressor filter for your system.
Regardless of your specific industry or application, a well-maintained air compressor plays a vital part in reducing energy consumption. Here are five top tips you can implement to increase the energy savings from your air compressor: 
