A mining complex was experiencing low pressure events — even though its 14 large compressors were all running. The pressure was adequate during most of the day, but during peak demand times, the pressure sagged to unacceptable levels. This, of course, caused complaints from the workers. The pressure settings of the compressors were already set […]

ELGi Compressors USA has introduced the EQ Series, a new range of oil-lubricated, direct drive rotary screw air compressors, designed to provide superior performance and reliability to small and medium-sized operations that traditionally use belt-driven air compressors. In line with ELGi’s customer-centric approach, the EQ ‘ELGi Quest’ Series is built for customers requiring reliable compressed […]

Industry 4.0 aims to increase efficiency, productivity, quality, and sustainability while optimizing supply chains and workforces. It sounds like a tall order, but as more manufacturers adopt the Industrial Internet of Things (IIoT), edge devices, and cloud-based technologies, the more such efforts are realized. Of course, one of the fundamental challenges is extracting and leveraging […]

When doing a compressed air audit, it is always recommended to measure the important parameters of the system and analyze the data carefully. Typically, pressure and power (or amps) are monitored, but in some cases measurement of flow comes in handy. In the case of a large plumbing component manufacturer, the installation of flow meters […]

A compressed air auditor was assessing a compressor and dryer installation within a compressor room and noticed something strange. On a large air dryer, the outlet flange was of 6-in. size, yet the piping used to connect the compressors and filters to the air dryer was only 4-in. Further to this, the long piping link […]

Measuring and repairing compressed air leaks can easily reduce energy costs by 10 to 20%. Compressed air is used in factories all over the world to control machines, processes, and pneumatic equipment. It is a safe and easily available medium and can be used in all possible places via hoses and pipes. However, compressed air […]

A compressed air auditor had a system of measuring devices that was monitoring a compressed air system located in a metal foundry. Pressure, flow, and compressor power were all monitored to help determine if the system was running efficiently and effectively. An additional set of instruments were added to the monitoring suite due to some […]

A compressed air auditor visited a large mine and was asked to look for areas of improvement. The mine’s manager was interested in reducing the electrical consumption and had a hunch that the compressed air system was a good item to investigate. The facility was a very mature site, so there were many large compressors […]

Recently, a compressed air auditor ran across a newly rebuilt compressor at a wood products company. The unit was cleaned up nicely and had a shiny new air end due to a rebuild — but because the unit had obsolete controls, this compressor continued to run very inefficiently. Saving money by rebuilding this compressor was […]

Quite often, people are surprised when they measure an air compressor and find the motor is consuming more than rated amps. One of the unfortunate things about the industry is that it is common to see motors are being stretched into the “service factor” in order to get more cfm out of a given compressor […]

One hidden problem in many compressed air systems is something called “artificial demand.” Many users are unaware of the effects of this component of compressed air demand as evidenced by higher than needed compressed air pressures on most systems.  Artificial demand in a compressed air system refers to the excess consumption of compressed air caused […]

Compressed air is useful for very many important tasks in facilities. However, due to the high cost of producing it, there are some end uses that are very wasteful. Air conditioning and ventilation is one such inappropriate end use. In a recent survey, a compressed air auditor found a surprisingly unique waste of compressed air […]

When the equipment is new and set up correctly, the coordination of VSD air compressors with fixed speed units is quite easy — if the number of compressors in the mix is four or less. Typically, what should happen is the VSD compressor maintains trim position with all combinations of fixed speed compressors providing base […]

A compressed air audit at a metal parts painting plant yielded some puzzling results. Pressure loggers were placed at the compressor discharge and in the plant, but the readings were showing an unexpected and significant pressure drop between the instruments. Visual checks showed that the only thing between the loggers was an air dryer with […]

By Ron Marshall You may have noticed some email signatures displaying the Certified CCASS symbol — and have become curious as to how that’s earned. Anyone, if properly prepared, can become certified by writing and passing an exam. The ease in preparing for the CAGI (Compressed Air and Gas Institute) Certified Compressed Air System Specialist […]

A compressed air auditor was monitoring a system in a plant that produces plastic film. Part of the measurement involved analyzing the flow from the compressor room and the dewpoint of the compressed air. When examining the data, a strange pattern developed on the flow and dewpoint profiles (Fig. 1). We can see the output […]

No one wants air compressor oil contaminating production. And in food processing applications, quality and safety are essential. E2M Kitchen, a fresh and ready-to-eat meal provider, knows this all too well. The Charlotte-based company significantly evolved its food preparation and packaging process for creating gluten-free, dairy-free, and preservative-free meals. Every tool used in its production […]

Two new managing directors strengthen the management team of the Sauer Compressors Group. The compressor manufacturer has appointed Nicole Fässler as CFO and Mladen Milcinovic as COO as of January 1. As CFO, business economist Nicole Fässler is responsible for the new management area of Finance, HR and IT. The Swiss national has extensive experience […]

It’s always frustrating to find water in a compressed air system, and especially so in locations where the air is supposed to be dry. During a recent compressed air audit, a survey of the piping found that poor dewpoints were being experienced in the system. Investigation found that significant amounts of free water mixed with […]

Most of the energy that goes into an air compressor comes out as heat, so it is always a good idea to direct the hot air produced to a location that needs heat — like into a plant in the winter season. The compressor in the photograph has a specially designed heat recovery system that […]

 Water-cooled compressors can have an advantage in locations where the ambient conditions are hot — and therefore using air cooled compressors would result in discharge temperatures that exceed the capacity of the air-drying systems. Overloading air dryers could result in free water entering the plant piping system. This would cause contamination of connected machines and […]

An air compressor at a metal processing plant had a troubled life. It started out as a VSD controlled machine, but a fire damaged the controls. Because of this, a new VSD was installed. It didn’t match the old drive, so wiring was altered to accommodate. Next, the drive failed due to dust contamination and […]

Hycomp Inc.’s technology has become part of Atlas Copco Group. The company designs, produces, sells and services specialized high-pressure oil-free compressors and boosters for a variety of industries. This is the second such acquisition by Altas Copco, which announced the acquisition of industrial gear pump manufacturer Kracht on January 3. Hycomp is a privately owned […]

A metal processing company had a laser cutter installed in its manufacturing plant to produce accurately fashioned pieces from metal sheets. This machine requires compressed air that is dried to about 35° F for general use but requires a small amount of air to keep the beam path clean —this avoids contaminating the expensive positioning […]

If you are carefully selecting your new compressors by looking at Compressed Air & Gas (CAGI) data sheets, you should be commended. Use of these sheets are a great way to compare compressor energy and flow characteristics between brands of compressors. In this way, you can choose the most efficient machine for your use and […]