Understanding Operating Characteristics of Industrial Air Compressors

If you’re considering purchasing an industrial air compressor near San Jose, you might be interested in learning more about how they function. If you are familiar with the basic parts and operation of an industrial air compressor, it will be easier for you to find the right air compressor for your facility’s needs. Here is a guide to understanding the operating characteristics of various industrial air compressors.

Reciprocating Air Compressors

Reciprocating air compressors are available in single-stage or multi-stage configurations. They operate by using a moving piston in an enclosed cylinder to draw air in, compress it, and force it back out. A single-stage air compressor draws air in and compresses it using one stroke of a piston. Multi-stage reciprocating air compressors draw air in and push it through an intercooler to cool it before compressing it further. The amount of times that the air is cooled depends upon how many stages the air compressor uses to operate. Multi-stage air compressors are more energy-efficient than single-stage compressors when used for large jobs.

Rotary Screw Air Compressors

Rotary screw air compressors are the most commonly used industrial air compressor. This option consists of two helical rotors that turn in synchronous mesh. Air is drawn into a space between the two rotating motors, and then forced through an inter-lobe cavity to a discharge port. These air compressors are ideal for facilities that operate for long hours, or even 24 hours per day. They can run for incredibly long periods of time without requiring air compressor repairs or maintenance. Rotary screw air compressors are the most energy-efficient and cost-effective choice for industrial air compressors.

Dynamic Air Compressors

Dynamic air compressors are oil-free air compressors that depend upon the transfer of energy from a rotating impeller to the air. They can produce a very high-pressure discharge, and operate at a much higher speed than other air compressor types. They are designed for high capacity jobs, as the flow of air through the air compressor is continuous.

See How Glass Bottles are Made

Most bottling facilities utilize industrial air compressors in San Jose to blow glass bottles. The type of industrial air compressor that is used will depend upon the size, shape, and style of the glass bottles being produced, as well as the production demands of the bottling facility. While almost everyone uses glass bottles in their day-to-day lives, not many are aware of the air compressor process by which glass bottles are produced.

Watch this video for a fascinating, step-by-step look at how glass bottles are made. You’ll learn about the materials that comprise glass, how the glass is melted, and how jars and bottles are then formed from the molten glass. Once the glass comes out of the glass mold, it enters a blow mold, where an industrial air compressor system stretches the glass and creates the final shape of the bottle.

Simple Strategies for Cutting Air Compressor Energy Costs

Whether you have a gas air compressor or an electric air compressor in San Jose, you can take certain steps to maximize its energy efficiency. The more efficient that your air compressor system is, the lower your energy costs will be. Here are some simple strategies for cutting your air compressor energy costs .

Conduct Regular Energy Audits and Air Compressor Inspections

Your air compressor’s efficiency depends upon a variety of factors. Air leaks can significantly reduce efficiency and cause energy bills to skyrocket. You should conduct regular, professional energy audits at your facility to determine if there are any areas that are affecting your air compressor’s efficiency. When evaluating these audits, look for days of the week or times of the day when more energy is consumed. You should also compare energy use over time to determine whether it is increasing. You can also arrange regular air compressor inspections to detect leaks or faulty parts that are causing the air compressor to consume more energy.

Install a Variable Speed Drive

Many air compressors operate by an on/off switch. Installing a variable speed drive on your air compressor will supply the required airflow while maintaining a stable pressure in the air pipes. This stability will ensure that extra energy isn’t being consumed at any point during the air compression process. A variable speed drive also reduces the need for air compressor repair and maintenance by limiting the air compressor’s starts and stops. Variable speed drives even offer effective leak detection, which can further improve the air compressor’s efficiency.

Invest in Efficient Air Compressor Repair Parts

If your air compressor is not as energy-efficient as it could be, you can always invest in efficient air compressor repair parts when necessary. For instance, a reluctance motor is an energy-efficient air compressor motor that can provide up to 21,000 kWh savings. This means that your energy costs can be reduced by up to $2,000 per year, on average. Your savings will be even higher depending upon your production demand and operating hours.

Draining an Air Compressor

In order to maintain the health and safety of your air compressor, it’s important that you know how to properly drain your air compressor tank in San Jose . If moisture builds up in the air compressor’s tank, your tank may erode or become rusted. This will necessitate costly air compressor repair parts, and will affect the efficiency of your air compressor.

Watch this video to learn how to safely and effectively drain an air compressor tank. You will learn where to find and how to operate your air compressor drain valve. To drain the air compressor tank, you must open the drain valve all the way. Depending upon how long the air compressor has been running, you may need to drain the air compressor tank after every use. Some people even prefer to leave the drain valve open until they need to use the air compressor again. This can reduce the need for air compressor repair parts.

Finding Ways to Reduce Waste in Your Air Compressor System

Air compressors near San Jose typically consume a lot of energy, and can significantly increase a facility’s gas or electric bills. You can maximize the energy efficiency of your air compressor and reduce the need for air compressor repair parts by identifying energy drains in your air compressor system. Here are some great tips for finding ways to reduce waste in your air compressor system.

Plug up Any Leaks

Leaks in your electric air compressor or gas air compressor system can cost your facility an extra $10,000 per year in energy bills. Even a small air compressor leak can significantly decrease your air compressor’s efficiency. Air leaks can also cause a drop in pressure in the air compressor system, which means that the air compressor will have to consume more energy in order to work effectively. When you eliminate air leaks, you can also eliminate other energy drains throughout the air compressor system. You can perform a visual inspection of the air compressor line to identify leaks, and then perform necessary air compressor repairs.

Operate at the Lowest Pressure Possible

Another common factor in air compressor efficiency is the pressure at which the air compressor system is operating. Tools are often operated at a much higher pressure than is necessary in order to maintain a higher production rate. This will waste energy, and can even impair the production output. You can perform an energy audit or monitor data regularly to determine what a reasonable pressure rate is for the demand of the job.

Perform Timely Air Compressor Repairs

One of the best ways to ensure that your medical compressor, portable air compressor, or rotary air compressor is operating efficiently is to be proactive about air compressor repairs and inspections. You should have a professional inspect your air compressor line and system to identify areas of waste and in need of repair. High quality air compressor repair parts are a necessary investment that can significantly improve an air compressor’s efficiency and function.

Boosting Your Business Efficiency with the Right Compressor

If your facility uses an air compressor in San Jose, you can decrease your energy costs and improve your facility’s productivity by choosing the right type of air compressor for your business. If your facility is small, your production demands are low, and your operating hours are minimal, you can get away with using a small air compressor. However, if your production demands are high and your facility regularly operates for long hours, you should consider an industrial air compressor.

Rotary screw air compressors are widely considered to be the most efficient of all industrial air compressor systems. A fixed speed rotary screw air compressor is ideal for moderate to high production demands, and can remain energy-efficient even when operating continuously for long periods of time.

Variable speed rotary screw air compressors allow you to adjust the speed and air pressure as needed depending upon the demands of the job. This allows the air compressor to operate as efficiently as possible, which will significantly lower your energy costs. The air compressor will also need fewer air compressor repairs and maintenance, as it won’t have to work as hard to meet your needs.

A Look at Air Compressor Options for the Bottling Industry

If you work in the bottling industry and are looking at air compressors for sale near San Jose, you have a few factors to consider. You will need to evaluate your bottling plant’s needs, the type of bottle that you’ll be working with, your maintenance capabilities, and the plant’s operating hours. Here is a look at the air compressor options that are available for the bottling industry.

Single-Stage and Two-Stage Air Compressors

Reciprocating air compressors are available in single-stage and two-stage configurations. Single-stage air compressors draw air in and compress air to the necessary pressure in one piston stroke. They can typically only reach pressures of 150 PSI, but have a higher cubic feet per minute rating. Two-stage air compressors compress air in two different steps or stages. The air is first drawn in and compressed to an initial air pressure. It is then piped through an intercooler to be compressed to a final pressure. They can operate up to pressures of 200 PSI, and are generally more energy-efficient at higher pressures. Single-stage and two-stage air compressors are best for smaller plants with minimal production demands and limited operating hours.

Three-Stage Air Compressors

Three-stage air compressors utilize a series of cylinders of different diameters. Between each stage of compression, the air is cooled in a heat exchanger. This reduces the amount of energy that is required to further compress the air. Three-stage air compressors are more efficient, reliable, and require fewer air compressor repairs than single-stage or two-stage air compressors. This makes them ideal for bottling plants that have a high output and that operate for long periods of time each day, as you can save a significant amount of money on operation, energy bills, and air compressor repair parts.

High-Pressure Air Compressors

High-pressure air compressors are best for bottling plants that always operate at a full load, as they offer long periods of time in between the need for air compressor repairs and maintenance. They are not energy-efficient for small jobs, and air compressor repair parts are typically costly.

Going Eco-Friendly with Oil-Free Air Compressors

If your facility is interested in becoming more eco-friendly, you should consider purchasing a small air compressor in San Jose that operates oil-free. Oil-free industrial air compressors are both efficient and environmentally friendly. They consume less energy as they compress air, which puts less demand upon your facility’s resources. They also do not emit or produce any harmful or hazardous waste, making them incredibly green.

An oil-free industrial air compressor can improve your facility’s air quality, as well. Because they don’t use oil to operate, they won’t generate harmful emissions that can be dangerous to employee health. Your employees will remain happy, healthy, and productive while operating an oil-free air compressor. FS Curtis compressors, Powerex compressors, and Almig compressors are all available in oil-free models.

Oil contamination can slow down production and ruin products, which may mean that your facility has to operate for longer hours to make up the difference. This taxes environmental resources further, as you will need to run equipment, lighting, heating, and cooling systems for longer than usual, thus consuming more energy and releasing more pollution. An oil-free air compressor eliminates the risk of delays and product contamination.