Air treatment is like life insurance for your air compressor; the more protected your system is, the longer it will last, and the less it will cost you in the long run.
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After all, getting clean, dry air is cheaper than ruining your jobs, buying a new compressor, or replacing your tools.
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This article covers the important things you need to know to keep your investment protected and fully operational for years to come.
Air Treatment Benefits - Why it Matters
The air treatment process cleans up and dries the compressed air you use to do work, along with regulating the temperature, too. If you don't use filtration, whatever materials that get into your storage tank can end up on your project and cause damage to your compressor system and air tools over time.
More importantly, hazardous particles (like atomized oil) can be sprayed into the air if an oil-separator isn't used, creating health concerns for anyone not wearing a respirator.
Filtering compressed air also plays a large role in the cost efficiency and longevity of your compressor, since clean air won't damage your air tools or cause leaks in your air lines from particulates scraping the walls in the air piping. After all, finding and fixing air leaks in your compressor system is more costly than preventative maintenance.
Parts of an Air Treatment System
Cleaning up and filtering compressed air can be done in multiple ways, and, if your compressor is properly sized, more air treatment is better than less. Each part of an air treatment system does a unique job, but all compressor components work together to give you the cleanest, dryest air possible. See the piping diagram below for a sample design of an air compressor system fitting together.
How Air Compressor Water Separators Work
When air is compressed it gets hot, and water vapor that was in the air is squeezed out of it (like wringing out a sponge) - condensing into a liquid mixture of water and oil.
Water separator line filters are specifically designed to remove that moisture from your air supply before it goes through your lines or storage tank, ensuring a dry, clean stream of air moves through the hose and your air tool.
Air compressor water separators usually come before the air tank in your air system.
Even with a separator, moisture will still build up in your tank over time. To prevent buildup, it's important to release this moisture from the tank. A convenient and efficient upgrade is to install an automatic drain valve, which automatically opens the drain and empties water without user intervention.
Types of Air-Line Filters
After excess moisture is removed from the air, other types of air compressor air filters can be used to further filter out remaining contaminants and particulates.
General-purpose air compressor filters are a good place to start since they can be used to remove moderate amounts of water, oil, and dirt from the line.
However, depending on your application, you may need a more powerful filter capable of removing contaminants as small as 0.01 microns, and combination filtration systems that remove both oil and water at the same point in the line are often used for these applications, called water-oil separators.
Pharmaceutical plants and labs often use carbon air filters (activated carbon filters) to remove oil vapors and odors from the air.
High-efficiency oil coalescing filters will go one step further and remove water and oil aerosol particulates up to 0.01 microns in size, effectively removing more than 99 percent of particulates from the compressed air, making them ideal for applications like auto-painting.
Learn: Air Line Filters
Lubricators
Lubricators are normally used to lubricate air tools and are attached right before your pneumatic tool/equipment.
Depending on the application, some pneumatic air tools need lubrication to operate correctly, and often times when air tool oilers are used, they are paired with a water separator to prevent moisture from getting into the air and causing damage to expensive equipment.
Although lubricators don't affect the overall treatment of the air, they are important to mention because they can be paired with other types of air-line filters or be used in custom setups in an industrial compressed air system, such as being used in tandem with a pneumatic actuator or solenoid valves.
Air Dryers
Compressed air dryers remove moisture from compressed air traveling through your air system and prevent damage to pneumatic tools, machinery, and in some cases, the product being worked on. Refrigerated air dryers are the best at removing the most water.
There are multiple varieties of compressed air dryers that serve different purposes, ranging from cycling and non-cycling refrigerated air dryers, non-cycling high-temperature dryers made to handle the high-heat setups when using compressors without an aftercooler, as well as membrane and desiccant air dryers that use different technologies to remove moisture from the air.
To ensure the correct operation of a desiccant dryer, an oil-coalescing filter must be placed before it in the air system.
Learn: Air Dryers
Air Compressor Piping Systems
There are many additional devices that can be installed to further clean the air and regulate airflow and pressure (PSI and CFM). After the treated air is dried, filtered, compressed, and stored, it will eventually travel through air delivery piping to the hose and air tool, called the
point-of-use.
Regulators and lubricators can be installed along the air piping line, giving you further control over air treatment as it gets to your air tool.
Heavy copper and black steel piping used to be the only options for building air lines to transport compressed air. It was expensive and labor-intensive to install in workshops and industrial spaces, and when air leaks occurred, it was difficult to repair or replace part of the line.
Today, new advances in piping technology make it much cheaper and easier to install and change the piping configuration of your piping to get compressed air where you need it.
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Companies like RapidAir and Transair have created air delivery systems that use aluminum and polyethylene piping with detachable joints that can bend and interlock in almost any configuration you can imagine, making it simpler than ever to change or replace a part of your line with much less effort.
Air Regulators
Regulators regulate air pressure and flow, and allow you to control the outlet pressure for precision and to avoid pressure spikes and drops at the point-of-use. They work like an air checkpoint that helps keep air pressure at the levels required for efficiency and safety.
Air regulators can be attached to any section of your air piping system, however, the best results are by installing them near the point of use. Regulators can control and restrict the airflow if necessary, and help prevent damage to your air tools due to pressure levels being too high for the tool.
Take Care of Your Air System
No matter what size your shop is, air treatment is critical to maintaining a long-lasting, dependable, and clean compressed air system that will continue to deliver year after year. However, just like the filter in your furnace, compressed air filters need to be cleaned and changed regularly, or they won't make much of a difference in the long run.
They say an ounce of prevention is worth a pound of cure, and with air treatment, this is true. Routine maintenance and the use of the filtration devices above will ensure your compressor is healthy and up to the task, no matter what your next project will be.
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Commercial Efficiency Navigation:
Various industries and applications often use compressed air as an energy source. Compressed air is essential in numerous processes and equipment, from manufacturing plants to dental offices and automotive workshops. Despite its extensive use, misconceptions and gaps in knowledge make it harder for people to know how to find the right compressor for their needs. However, you can easily choose the right industrial compressor with this buyer’s guide.
What Is Compressed Air?
Compressed air involves compressing atmospheric air to increase its pressure for various applications. This process typically requires an air compressor that intakes atmospheric air and pressurizes it for use in different tools or systems. Once compressed, you can store the air in tanks or directly use them to power devices and equipment. The ability to store and transport energy makes compressed air a versatile and valuable resource in many settings.
Why Do People Use Compressed Air?
Compressed air serves diverse purposes, including powering pneumatic tools and machinery, controlling valves and actuators, and providing clean air for breathing purposes. Its versatility and adaptability make it a popular choice in various sectors, such as manufacturing, construction, healthcare, and transportation. Industries often prefer pneumatic systems powered by compressed air due to their reliability, safety, and ease of maintenance.
How Do You Measure Compressed Air?
Measuring the pressure of compressed air means using units such as pounds per square inch (psi) or kilopascal (kPa). Meanwhile, you can gauge the volume of compressed air using cubic feet per minute (cfm) or liters per minute (L/min). These measurements are crucial for selecting the appropriate compressor size and type for different applications to ensure efficient operation and energy use.
Understand Your Company’s Needs
Buyers must have a clear understanding of what their company needs before purchasing an air compressor. Start by identifying the scope of your purchasing responsibilities, which may include everything from office supplies to high-value technology. Determine specific requirements for each purchase, such as quantity, quality standards, and delivery timelines.
Knowledge of your company’s objectives, such as enhancing productivity or reducing costs, along with budget constraints and strategic goals, will help you make the right purchasing decision. Select suppliers that align with the company’s immediate needs and long-term goals. This understanding is the foundation of your role, ensuring that every purchase supports broader company objectives.
Research Potential Suppliers
Conduct thorough research into potential suppliers to ensure they are reliable, reputable, and capable of meeting your company’s requirements. Begin by assessing their history, including their past performance in terms of delivery accuracy and adherence to quality standards. Review their quality control processes to understand how they maintain product standards.
Also, analyze their pricing strategies to ensure competitive rates and evaluate their delivery capabilities to meet your timelines. Considering their financial stability, ethical practices, and customer reviews will also help you build a comprehensive profile so you can know what you’re buying.
Build Relationships With Suppliers
Developing strong relationships with suppliers is crucial to successful purchasing. By building trust and open communication channels, you can negotiate better deals, receive priority service, and create long-term partnerships that benefit both parties. Hosting quarterly or monthly meetings and consistent communication through emails or video calls can foster a collaborative environment. Strong relationships can also result in mutual growth, as your success can lead to increased business for your suppliers.
Keep Track of Market Trends
Stay updated on market trends, including changes in supplier prices or the availability of certain products or services. This information can help you make informed purchasing decisions and anticipate potential supply chain disruptions, such as shortages or increased lead times. Understanding these trends can also provide a competitive advantage, allowing your company to adapt quickly to market conditions. Regularly reviewing industry reports, attending trade shows, and networking with peers can also help you stay on top of the market and keep your company ahead of the curve.
Negotiate Effectively
Effective negotiation skills are essential for buyers to ensure cost-effective purchasing. Be confident in communicating your company’s needs and expectations while being open to compromise. Approach negotiations with a clear understanding of your objectives and the supplier’s perspective. Aim for a win-win situation where both parties feel satisfied with the agreement.
Monitor Supplier Performance
Monitoring supplier performance is crucial to ensure they meet the agreed-upon terms and quality standards. Keep track of delivery times, checking for promptness and reliability, as well as product quality, to ensure everything meets your expectations. Also, evaluate customer service levels to promptly identify any issues.
Regular performance reviews, such as quarterly evaluations and feedback sessions, can also help you maintain high standards and foster continuous improvement in your business. Thankfully, when you address concerns early, you can work with suppliers and find the air compressor that helps you prevent future disruptions.
Review Contracts Carefully
Review the supplier’s contract before signing to ensure all terms are fair and favorable for your company. Pay attention to key components such as:
- Delivery schedules
- Payment terms
- Confidentiality clauses
- Legal obligations
Make sure the terms regarding penalties for non-compliance or late deliveries are clear. Seeking legal advice will help you avoid potential risks or loopholes that could negatively impact your company. A thorough review safeguards your company’s interests and establishes a strong relationship with your suppliers.
Communicate Clearly
Effective communication is a cornerstone of the purchasing process. Make sure you clearly communicate your company’s needs, expectations, and any changes in requirements or deadlines to suppliers to avoid misunderstandings. This communication involves sending emails and making calls while building strong relationships with suppliers through regular updates and feedback sessions. Developing strong communication skills can also boost collaboration, foster trust, and lead to more successful outcomes for your business.
Continuously Improve
Always strive for continuous improvement in your processes and decision-making. Seek feedback from suppliers and colleagues to identify areas of improvement and implement necessary changes to enhance your performance. Embracing new technologies, methodologies, and best practices will also help you stay ahead in the purchasing field. This continuous improvement might involve:
- Adopting innovative procurement software
- Attending professional development courses
- Participating in industry forums
Learning more about air compressors and the market can help you navigate the purchase process with confidence.
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