Air Compressors

The Energy Services Act is a key piece of legislation in Germany that aligns with the EU Energy Efficiency Directive. It mandates that large enterprises conduct regular audits to improve energy efficiency and reduce overall consumption or potentially face fines up to €50,000. Such legislation drives technology innovation and increases the adoption of efficient machinery, […]

Often during audits of compressed air system, we find that operating staff have no clue as to how their equipment works. This causes so much trouble regarding operation and maintenance. Many people who work with compressed air systems know how to turn the equipment on and off. But when it comes to really understanding how […]

In cold climates, compressor rooms that draw 100% outside air for ventilation face a challenge: how do you prevent freezing temperatures from damaging equipment? The common solution is to install electric heaters. But while it seems simple, relying on electric resistance heating to temper a compressor room is often a costly mistake — especially when […]

By Ron Marshall If you’re running air compressors in your facility, you might be sitting on a gold mine of wasted energy — literally. Up to 94% of the electrical energy used by an air compressor is converted into heat. The good news? Most of that heat is recoverable. The better news? You can turn […]

How do you decide when to remove your compressed air filter elements? If you are using the differential gauge to tell you when, that could be a mistake. Compressed air is widely used in manufacturing, but contamination is a major concern. To maintain air quality, compressed air systems rely on filters — particularly coalescing and […]

A company producing vinyl siding was using a lower pressure blower to blow water off the product as it came out of its production machine. But the blower failed, and the staff quickly rigged up some compressed air nozzles consuming about 50 cfm. An air auditor noticed this misuse and flagged it as an inappropriate […]

Emerson will demonstrate how it is transforming the future of factory automation through its proven Floor to Cloud approach and comprehensive portfolio at Hannover Messe in Hannover, Germany, on March 31 to April 4. Visitors to the Emerson booth in Hall 11, Booth C30, will learn how companies of any size can apply a Floor […]

Running a lubricated screw compressor at light loading can lead to a critical issue known as oil carryover, where excess lubrication oil escapes the compressor into the downstream air system. This problem, while often overlooked, can result in costly operational challenges, particularly in food processing plants where air purity is critical. Lubricated screw compressors rely […]

During a walk-through audit, a compressed air auditor noticed a pail collecting lubricant from a filter drain. The pail was almost completely full, causing the auditor some concern. He knew that this was a sign of several possible problems. High oil or lubricant accumulation downstream of a lubricated screw compressor is often caused by issues […]

Tsunami Compressed Air Solutions, a division of Suburban Manufacturing Group, introduces the Tsunami Aftercooler, a high-performance solution designed to pre-cool compressed air before it reaches the downstream equipment, maximizing moisture removal and improving system efficiency. With six versatile mounting configurations, a space-saving wall-mounted design, and a powerful cooling system featuring a high-volume fan and finned […]

By Ron Marshall An industrial plant started having trouble with its air dryer. No matter what the maintenance personnel tried, they could not achieve adequate dew point values. Nobody suspected the upstream condensate drain — especially because, when tested, it did not release any excess condensate or oil. Finally, it was disassembled and found to […]

A compressed air auditor did a study at a plastic products plant. Before the study, the maintenance manager had mentioned he was extremely proud that he had 100% redundancy in his system. After the study, the auditor had to tell him some bad news — every one of his compressors were running to service his […]

Elgi Equipments has introduced its pioneering compressed air stabilization technology. Designed to revolutionize the way compressors operate in plants with dynamic air demand, the Stabilisor system aims to address the longstanding challenges of unstable compressor performance, inefficiency, and excessive wear caused by frequent load/unload cycles. In industrial settings, the gap between compressor capacity and plant […]

Compressed air leaks are a silent and costly thief of energy, often accounting for 20-30% of wasted energy in industrial systems. While leaks can happen naturally over time, poor practices can accelerate their creation. Understanding the role of piping, end-use equipment, and maintenance in contributing to leaks can help highlight the importance of good practices. […]

ELGi North America announced the launch of the Airmate HLD series modular desiccant compressed air dryer, a state-of-the-art solution for applications that demand ultra dry compressed air. Engineered to achieve ISO 8573-1:2010 Class 2 compressed air quality, the new desiccant air dryer consistently maintains –40°C pressure dew points. This meets the demanding requirements of industries […]

By Ron Marshall A compressed air pressure/flow controller is a device designed to regulate the pressure and flow of compressed air delivered to a system, ensuring consistent performance and efficiency. It acts as a buffer between the supply and demand sides of the system, maintaining steady downstream pressure despite fluctuations in demand or upstream conditions. […]

The development of acoustic imagers has transformed the way compressed air leak audits are done, saving time for the user. Acoustic imagers are advanced tools used to detect gas leaks by capturing and visualizing high-frequency sounds that are typically inaudible to the human ear. When compressed air or gas escapes through cracks, holes, or loose […]

“Inside the box” thinking involves sticking to conventional methods and solutions that are tried and tested. For example: Routine maintenance: Regularly replacing filters and addressing leaks are standard practices to improve efficiency. Equipment upgrades: Replacing old compressors with newer, more energy-efficient models is a typical step. Basic monitoring: Installing pressure gauges and ensuring the system […]

By Ron Marshall Improving the efficiency of your air compressor system doesn’t always require a large investment. Small, cost-effective changes can lead to significant energy savings, reduced operational costs, and a longer system lifespan. Here are five practical and low-cost strategies to boost the efficiency of your air compressor.   Fix leaks Air leaks are […]

Compressed air systems naturally generate condensate as moisture in the air condenses during compression and cooling. If this condensate is not properly managed, it can accumulate in the system, particularly in uninsulated outdoor pipes. During winter, when temperatures drop below freezing, this condensate can turn into ice, leading to significant operational and safety issues. Freezing […]

By Ron Marshall The short answer is “as cool as possible, but not below freezing.” The practical answer is uncomfortably cool, in the range of 50° to 60° F. Keeping the temperature low reduces the amount of condensed moisture in the discharge air and makes things easier for the air dryer. Compressors generate significant heat […]

A compressed air auditor was performing his work at a large mining operation. He and the site electrician were opening up the various machine electrical panels to enable power factor testing. Within seconds of opening one compressor panel, the electrician jumped back with fright and informed the auditor he was going to be a while. […]

When working with desiccant-style compressed air dryers, there are several factors to consider, to ensure optimal performance and efficiency. Desiccant dryers rely on two towers filled with desiccant material that alternately dry the air and regenerate, to maintain continuous operation. The regenerative purge is essential to removing the moisture collected by the desiccant, but it […]

Preparing an industrial compressed air system for cold winter conditions is essential to ensure reliable operation, prevent equipment failures, and avoid costly downtime. Cold weather introduces unique challenges, such as moisture buildup, freezing, and increased system stress — all of which must be addressed to keep the system running efficiently. Proactive preparation can safeguard your […]

When performing leakage detection on your compressed air system with your ultrasonic leak detector (if you don’t have one, good grief, run out and get one!), you will run across various leaks in piping and equipment. Many of these are small, so roughly less than $100 value per year. But quite often, you will find […]