Air Preparation

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 […]

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 […]

Do you know how much air your compressed air system is consuming? How about the level of waste during non-production? If you don’t, it may be time to purchase a flowmeter to find out the answers to these questions. Recently during a leak assessment, a compressed air auditor was surprised to see 46 cfm flowing […]

The typical piping installed in industrial plants and shops is made of steel, and as a result may be subject to rusting and contamination. Fig. 1 and 2 show what was found at a heavy industrial plant with the air compressors taking in polluted air. Rusting and contamination in compressed air system piping can lead […]

Normally when measuring the pressure gradient of a compressed air system in an industrial site, the pressure at the compressor discharge is the highest of all locations. Once the compressed air travels through piping, filters, air dryers, and other components — each causing restriction to flow — the pressure at the far end of the […]

Increase efficiency and effectiveness by choosing the right pneumatic control or regulation product for accurate, repeatable results. By Mindy Schoeff, Marketing Communications Manager, Proportion-Air Facilities that manufacture packaging products, or those that do the actual packaging, are no strangers to pneumatic control. Whether pressing a product, filling it, conveying or moving materials, testing or sealing, […]

I found a leak, it’s hissing loud, Compressed air whistling, oh so proud. I grabbed some duct tape, rolled it tight, Thinking I’d fix this leak tonight. But oh, that tape — it flaps and flails, Like it’s on a ship with stormy sails. The air just laughed, a mocking squeak, “You can’t fix me, […]

In this blog post, we will discuss the fifth of five industrial compressor capacity control modes. A very efficient method of controlling a compressor at part load using variable speed mode. With this type of compressor, an electronic drive is fitted to a specially designed compressor with air end components matched to the intended speed […]

In this blog post, we will discuss the third of five industrial compressor capacity control modes. A moderately efficient method of controlling a compressor at part load uses load/unload mode with adequately sized storage receiver capacity. With this mode, a pressure switch, or electronic control, is used to provide load and unload signals to the […]

In this blog post, we will discuss the second of five industrial compressor capacity control modes. The least efficient method of controlling a compressor at part load is using modulating mode by way of pneumatically controlled inlet valve control. With this mode, a pneumatic system detects the compressor discharge pressure and compares it to a […]

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 […]