With continuous efforts by compressor manufacturers to lead the market on energy efficiency, superior performance, and reliability, it is critically important that the users of air compressors are aware of the advanced product options available in the market. The technological advances in control systems and the evolution of the Internet of Things (IoT) provide further motivation to upgrade the air compressors at the right time. Typically, Air Compressor Upgrades happen in every 3-4 years by manufacturers to improve energy efficiency, reliability, advanced features, etc., and it is worth the while to evaluate the need for upgrading your compressors.

Five critical factors to consider while upgrading your compressor

Energy Efficiency: Energy costs contribute to over 75% of the total life cycle cost (LCC) of a compressor, and is therefore the key factor in upgrading an air compressor. Once the energy cost of the existing compressor is determined (through air audit or a simpler total input power measurement), the benefits of a new compressor, in terms of energy costs, can be evaluated. In cases where the user’s duty cycle of the air compressor has increased significantly over time due to additional production activities, the savings will be more beneficial with shorter return on investment. Additionally, if the plant needs a higher flow for expansion, it is an opportunity to consolidate the need and evaluate for upgradation. The size of the machine (in kW) should also be considered, as the larger the size of the unit, the higher the savings potential.

Advanced features: Significant improvement in controller features, more intelligence through additional sensors, and evolution of IoT capability are further reasons to consider an upgrade. These features result in improved uptime, insights for improvement in energy efficiency, and inputs for optimized operational settings in addition to 24×7 remote monitoring from anywhere in the world. In plants where the failure of a compressed air system can result in heavy losses in productivity, these features are particularly critical. Improvement in consumables’ life and/or reliability is another factor. Recently, ELGi had doubled the life of oil filters used in its oil lubricated rotary screw compressors in several models. All these features not only make the compressors more efficient but also significantly more reliable and advanced.

Breakthrough products: Compressor users must also look out for breakthrough products that will result in superior performance. ELGi has recently launched a product, AB Series with a disruptive oil-free technology that will bring down the life cycle cost of an oil-free compressor significantly. Such breakthrough improvements provide an opportunity to improve overall plant efficiency and performance while meeting the users’ needs effectively. Growing production needs in a plant will also need a different compressor technology such as the transition to centrifugal compressors for larger volumes of compressed air as an example.

Unplanned maintenance costs: As compressors age and when they need frequent attention to keep them running reliably, the unplanned maintenance or repair costs will also increase. If the cost of repairs reaches a certain level (~40-50% of the compressor value), along with the lower energy efficiency of older products, it is an appropriate time to evaluate and upgrade your air compressor.

Return of Investment (RoI): Another important factor to be considered while upgrading the compressor is the RoI. With improv energy costs, the RoI can be evaluated to meet the customer’s target.

Their distinct features can be understood in terms of:

While on one hand we see, there is an increase in operating costs, we have also to be mindful of the impact a process/ product has on the environment. Delivering quality and superiority of product, is the need of the hour!

Hence industries are challenging existing norms and looking for innovative solutions to their quality compressed air needs. From this perspective, Oil Free Compressors are emerging as a preferred solution & ideal choice.

What are Technical oil-free compressors?

In applications where compressed air directly comes in contact with the product being processed, throughout the process, manufacturers must ensure there are absolutely no impurities. In such cases Oil-free screw compressors are the preferred choice as they compress the air inside an oil-free compression chamber, which is effectively sealed to prevent lubrication oil from contaminating the compressed air.

Traditional oil-lubricated compressors or oil injected compressors are predominantly used in oil free applications with downstream filters. This arrangement delivers “Class 1” oil quality standards, which means the air will have about 0.01 mg/m3 of oil residue.

This does not meet the global compliance requirements of ISO 8573-1:2010 and ISO 8573-7. To ensure that no residual oil, airborne particulates or vapour can enter the downstream system, they must be connected with downstream air dryers and double line filters to further purify the air. This is termed as “Technical Oil Free”.

This approach appears to be cost-effective, but in reality, it results in high operation cost and higher life cycle costs.

Technical Oil Free systems also have an environmental impact

1. Approximately, 2-3ppm of oil will be continuously carried into the application and into the atmosphere. This loss of oil must be continuously topped up for the entire operating life of the compressor & is a hidden cost.
2. The condensate from the compressor and the downstream filters will contain traces of oil. Due to strict environmental regulations, additionally, an oil/water separator must be used, to remove the oil before letting the condensate into the atmosphere.

The French fry from Belgium

So, how did the French-fry get its name? Back in the 1600s, as lore goes, villagers living in Meuse Valley, accustomed to frying and eating fish, fried potatoes as well – the same way they prepared fish. This is how the first fry is said to have been created. A few decades later, during WW1, American soldiers stationed in Belgium were introduced to the potato fry. The official language of the Belgium army at the time was French, which is why the American soldiers nicknamed the potato snack ‘french-fries.’ From then to now, this name has stuck.

In our fight against the Coronavirus, PPE products have become an essential requirement for the protection of every individual at the frontline, from doctors & medical staff, to policemen, cleaning staff and security & delivery personnel.

Textile units have started allocating their resources towards the production of such protective gear, adjusting to the needs of a changing world.

The global food and grocery retail market are expected to reach USD 12.24 trillion by 2020, according to a new report by Grand View Research, Inc., progressing at a CAGR of 6.9%. This proposed growth will be driven by countries in the Asia-Pacific region, including India, China and Indonesia.

The rising population and increased affordability of premium foods and grocery products have created a need for regulatory standards. Interestingly, compressed air has become the essential power source for countless manufacturers in the food & beverage industry to maintain safety and quality while meeting the growing demands.