Putting a Price on Air Compressor Downtime [INFOGRAPHIC]

When it comes to your air compressors, time is money. Any time your compressor goes down, your business is down as well. The costs of that downtime can add up significantly. You may fall behind on orders or miss out on new business because you are unable to deliver. Whether you have a medical compressor, industrial air compressor, or other compressor type, preventative maintenance is key across the board. By maintaining your air compressors, you can maximize their efficiency, lower your energy costs, and reduce the risk of costly downtimes. Find out more about the true cost of air compressor downtime in this infographic from D&D Compressor Inc . We sell and service air compressors near San Jose and can help your business meet you needs. Share this information with about the importance of air compressor repair and maintenance with your co-workers and others in your industry. Air Compressor Downtime Infographic

What’s the Relationship Between Pressure and Flow?

Are you looking to optimize your existing compressed air system or looking to buy a new air compressor in San Jose? In either case, it’s important that you understand the relationship between pressure and flow in a compressed air system. In addition to affecting the overall performance of a compressed air system , pressure and flow can also affect an air compressor’s operating costs. To help you save money and get the best performance from your existing or new air compressor, here’s a closer look at the relationship between pressure and flow.

Artificial Demand Increases Energy Usage

In a compressed air system, “artificial demand” refers to the practice of supplying more pressure to the air compressor than necessary. For example, if 75 psi is needed to maintain steady production and the compressed air header is set at 100 psi, the artificial demand is 25 psi. As a general rule of thumb, every 2-psi increase in discharge pressure measured at the compressor increased energy by 1%. In the aforementioned example, the air compressor’s artificial demand results in a 12% increase in energy usage, which can equate to thousands of dollars in excess energy costs annually.

Higher Pressure and Flow Increases Maintenance Overhead

In addition to increasing operating costs, non-optimal pressure and flow levels can also increase maintenance overhead. The higher the pressure and flow, the more heat that is generated in the compressor and the shorter the intervals between service appointments. Unnecessary pressure and flow settings can also reduce the air compressor’s operating life, which means you’ll have to invest in new air compressors more frequently.

Determining Critical Pressure

There are formulas for determining the critical pressure in a production process , but it’s also important to consider the overall design and implementation of your compressed air system. For example, you must first ensure that the industrial air compressor you purchase is properly sized for your operation. An air compressor solutions provider in San Jose can help you size the right system based and determine the critical pressure of your new air compressor.

What You Need to Know About Choosing a PET Air Compressor

If you’re in the market for an industrial PET air compressor system in San Jose , you need to make sure that the solution you choose is capable of meeting your industrial or manufacturing needs. Air compressor solutions providers in the Bay Area can help you select the best system given your specific requirements, needs, and parameters, but in the meantime here are some factors to consider as you look for a PET air compressor system.

Air Quality

Air quality is a major concern for bottle-blowing companies, since the quality of the compressed air can affect bottle taste and odor. Although different PET air compressor systems offer different levels of air quality assurance, filtration should be one of your primary concerns when looking for a compressed air system. A multi-stage filtration system will help to ensure that air quality is maintained to ISO requirements for bottle-blowing operations.

Operation Hours

When selecting a PET air compressor, it’s important that you consider the number of hours the equipment will be running per year. Single-shift operation five days per week equates to approximately 2,000 hours annually, which is appropriate for smaller air-cooled units. For higher production hours, consider a larger water-cooled unit since they are better designed to put up with higher and more rigorous production demands.

Blow Pressure

There are multiple factors to consider when determining blow pressure requirements, including bottle design and machine speed, but you should also take maintenance and power costs into account. That’s because the higher the blow pressure, the more heat is generated within the PET air compressor—which means shorter maintenance intervals and higher power costs. An industrial air compressor solutions company in San Jose can help you select a PET compressed air system that provides optimal blow pressure while keeping maintenance and operating costs to a minimum.

The Importance of Air Compressor Filters

Just how important is the air quality inside a compressor system? Depending on the type of air compressor you have and the application it’s used in, air quality may very well be one of the most important concerns. That’s because sanitary air impacts a number of different factors and elements regarding the performance, efficiency, and durability of certain compressed air systems. Watch this video to learn just how important air compressor filters really are.

In addition to increasing efficiency through optimal filtration, compressed air filter systems also protect the equipment and can actually extend the life of an air compressor system by removing contaminants that might otherwise circulate within the equipment and cause problems later on. From this perspective, investing in a quality air drying and filtering system can save you time and money in the long run by increasing efficiency, minimizing service, and prolonging the service life of your air compressor. To achieve these benefits and more, work with an air compressor supply company in San Jose to find the perfect filtration system for your equipment.

The Benefits of Outsourcing Compressed Air as a Utility

Manufacturing and processing plants don’t generate their own power, supply their own water, or deliver their own natural gas, so why shouldn’t they treat compressed air in a similar manner? Treating compressed air like a utility is a relatively new concept among the industrial and manufacturing industries, but those plants and facilities that have adopted the compressed air as a utility model have enjoyed tremendous benefits. If you’re upgrading or upsizing your industrial air compressor system in San Jose , you might also want to consider the benefits of treating compressed air as a true utility and outsourcing the process.

Optimized Air Delivery

Compressed air “utility” companies will design a system specifically configured and calibrated for your plant’s load profile, which is achieved by measuring the free air delivery, load time, and total kWh of each of your air compressors. Optimized air delivery is the first step towards a more efficient air compressor system, which ultimately means lower operating costs.

Lower Operating Costs

Even after taking the fees into account for outsourcing compressed air as a utility, there are significant financial benefits to going this route. As mentioned previously, compressed air providers are able to achieve optimal air delivery to streamline compressor usage and yield significant energy savings compared to non-optimized air compressor systems. How much you stand to save depends on the size, type, and number of air compressors currently in use.

Less Overhead

In addition to lower operating costs, you also stand to save a considerable amount of money on maintenance and service costs. Outsourcing compressed air puts 100% of the associated service and maintenance costs on the compressed air company. Not only does this represent additional cost savings for your organization but also greater peace of mind that should any problems develop, air compressor service technicians will be there quickly to address the issue and get your plant up and running as quickly as possible.

Spotlight on Air Dryers and Filters

Compressed air that is properly treated will not only increase the efficiency and productivity of your air compressor equipment, but will also ensure that the equipment adheres to quality standards that might otherwise result in fines or costly delays while your system is brought up to code. That’s why it’s important to start out with an air dryer and filtration system to ensure the quality of your compressed air. Air drying and filtering systems are able to remove impurities from the air to improve compressor efficiency and its process quality. Look for air dryer and filtration systems from top brands such as Beko, Pneumatech, Parker/Zander, NANO, and Zeks.

If you rely on an industrial air compressor, it’s important that you use the best parts and accessories to keep your equipment running smoothly. That’s why it’s important that you purchase air compressor repair parts and upgrade equipment from a reputable supplier in San Jose that can recommend the best solutions for your specific equipment and application.

Flow Metering in Large Air Compressor Systems

Achieving optimal pressure and flow in a compressed air system is important for minimizing maintenance and operating costs. When investing in a new industrial air compressor in San Jose , the first and most important thing is that you size the system appropriately for your specific production needs. After that, the process of maintaining system efficiency (and keeping operating and maintenance costs low) falls on your shoulders, or on the shoulders of whoever is tasked with overseeing the compressed air system. Flow metering offers significant opportunities to reduce energy costs and extend a compressor’s service life. Here’s what you need to know about flow measurement in large air compressor systems.

Thermal Mass Flow Meter

Although there are many different types of low-cost electronic air compressor metering instruments available, the most popular is the thermal mass flow meter (which is principally based on a design that dates back to 1914). Modern thermal mass flow meters provide accurate signal output without being affected by changes in air pressure or temperature, two factors that can affect the performance and accuracy of other flow metering devices.

Main Supply Header

When planning for the implementation of a flow metering device in your compressed air system , experts recommend compressed air flow meters be installed in the main supply header to provide the most accurate usage profile. It’s also recommended that a flow meter be installed somewhere in the delivery piping where the compressed air is clean and dry.

Non-Production Metering

When combined with electrical consumption readings, flow meters provide the basis for measuring the efficiency of an industrial air compressor. However, it’s important not to ignore measurements during non-production hours. Measuring flow during non-production hours can provide critical information on leakage rates or inappropriate uses of compressed air, such as blowing off workstations. Combining this information with your plant’s compressed air usage profile will allow you to achieve optimal system efficiency for lower production and maintenance costs associated with your industrial air compressor.

Choosing Your Next Air Compressor

With so many different options available on the market, how do you know which air compressor is right for you? This excellent video primarily focuses on the different factors to consider when choosing a portable air compressor, such as the environment in which you work and the type of tools or equipment you need to power with an air compressor. This video also touches on the different types of portable air compressors so you can narrow down your search.

Whether you’re purchasing a portable air compressor for your work truck or designing an industrial compressed air delivery system for a large plant or processing facility, the air compressor you choose will have a big impact on productivity and quality. That’s why it’s important to work closely with a reputable air compressor provider in San Jose to get expert advice and recommendations based on your specific needs. There are a lot of different air compressors to choose from, so work with an expert to make sure you select the perfect one.