In this blog post, we will discuss the first of five industrial compressor capacity control modes. The simplest method of controlling a compressor is Start/Stop mode using pressure switch control. This control simply turns on the compressor to run at full load when the pressure hits a lower pressure level — and turns off the […]

 There are five different capacity control modes available for use with North American-built large industrial air compressors. It pays to know how each mode works, especially if you operate or service air compressors or happen to have your compressors operating in one of the least efficient modes. The accompanying photograph shows just one design that […]

  A compressed air auditor regularly flow-tested the compressors under his study. This generally would be done if the air compressor was drawing low amps — a telltale sign that the unit is producing low flow output — or if the compressor has excessive hours. Often times, internal wear due to age will reduce output […]

It is common to see the air in a complete plant dried by a desiccant dryer only to service one small end-use that is subject to freezing temperatures. The purge from a large desiccant dryer is much more costly than that of a small point-of-use dryer, which can be placed on the outdoor feed. The […]

A compressed air auditor was excited to see logbooks for each of the compressors at a large mineral processing facility. Each book was protected from the environment by a really nice orange plastic case. The auditor was interested to see the compressor history and opened the book, only to discover it was blank — no […]

A compressed air auditor recently performed an energy audit at a mineral processing facility. Plant personnel were constantly complaining about production outages due to low pressure. The problem was that when the pressure dips down below 80 psi, the drive clutches on the large ball mills — that grind the processed down minerals to powder […]

Did you know that garbage bags have a use in the compressed air industry? The use of garbage bags to determine compressed air leakage, is described in the U.S. Department of Energy’s (USDOE) MEASUR tool and is a straightforward and cost-effective method for roughly estimating air leaks in a compressed air system. This technique is […]

Festo introduces a line of pre-configured, assembled, and tested compressed air preparation units that not only makes specification and ordering faster and easier, but also ensures clean air in food and beverage production. Right out of the box, the new units meet the Safe Quality Food (SQF) guidelines of final filtration stage 0.01 micron (µm) […]

Corrosion in steel pipes and storage receivers within compressed air systems is a common issue that can significantly impact system efficiency, safety, and longevity. This process is primarily driven by the presence of water and acid condensate, both of which are common byproducts in compressed air environments. Understanding how corrosion occurs can help in implementing […]

Dust collector reverse pulse cleaning is commonly deployed in any industry that creates powdered dust. Through the years, it is common to see expensive failures of these devices that consume excessive amounts of compressed air. Often times, these failures go undetected. Dust collector reverse pulse cleaning is a highly efficient method for removing accumulated dust […]

Electro-pneumatic pressure regulation and flow control manufacturer Proportion-Air recently celebrated the completion of its new facility in Gulf Breeze, Florida, with a grand opening event last month. The event brought visitors from the community to see the company’s new 12,000 square foot building, which houses research and development, marketing and sales, and administration functions. Attendees […]

Air-cooled air compressors are crucial to keeping the production process running in many industries; they work by turning power into usable energy. Their performance, however, depends heavily on their ability to stay cool. If dust and debris clog up a compressor, it can overheat, work less efficiently, and cost more to operate. Fig. 1 and […]

Tom, a diligent plant engineer at a mid-sized manufacturing facility, faced persistent problems with his compressed air system powering his crucial production lines. Despite repeated attempts to fix various symptoms — frequent drops in pressure, excessive energy consumption, and sporadic equipment failures — the problems persisted, causing costly downtime and frustration on the factory floor. […]

A wood products company had an aging heatless 1,000 cfm desiccant air dryer, being used to condition the compressed air produced by two 100-hp compressors in their processing facility. After working for many years, the dryer controller failed and had to be replaced. Replacement parts could not be found, so the local electricians came up […]