Like any other machine, air compressors need regular maintenance and periodic replacement of parts that get strained with continuous use. By changing the worn-out components in time, you can ensure optimal functioning and better durability of your unit while also saving time and money on unnecessary repairs. 

While these spare parts are often available in the market, and in many instances even come at attractive price-points, it is critical to procure your air compressor’s components only from Original Equipment Manufacturers (OEMs).  

Benefits you enjoy when you purchase only genuine parts:  

• Warranty – for repair, replacement or refund if the part fails to function optimally  
• High product quality  
• Longer lifespan  
• Higher productivity  
• More energy savings  
• High reliability  
• Ease of service and maintenance  

Let’s take a look at the parts that need to be replaced or replenished for the commonly used rotary screw air compressors:  

Dust filters and oil separators  

The air & oil filters and the oil separators are critical parts of air compressors as they prevent damage and performance loss caused by dirt in the internal system.  

Dust particles from inlet air can damage your air compressor’s rotors. This can reduce the quantity of compressed air delivered to associated tools, with continuous energy consumption.  

Dust also lowers the lifespan of the air compressor element and the oil separator. When it gets mixed with the oil that lubricates the rotary screw air compressor, the oil becomes impure and less effective.  

Additionally, dust harms the bearings and the bearing housing, negatively impacting the air compressor element and may even lead to element seizure. 

Therefore, it is essential to use only genuine air compressor filters and oil separators when it is time to replace the originally-fitted units. Such filters have strong dirt reduction capabilities. They are devised to endure high operating pressures and fluctuating temperatures while maintaining efficient performance with low power consumption.  

Airline filter cartridge   

If you replace your air compressor’s line filter cartridge with a counterfeit piece, it will reduce the filter’s efficiency and allow dirt particles to enter the air network. This will result in pressure drops and high energy consumption by the compressed air system.  

Using a non-genuine filter cartridge will also result in more frequent replacements or repairs, leading to a higher total lifecycle cost of the air compressor. Hence, always insist on buying genuine airline filters.  

Lubricating oil 

A key consumable in oil-based air compressors, is that the lubricating oil absorbs heat while also safeguarding the unit from dust accumulation and rusting.  

While some users have a notion that ‘any oil’ can be used for lubrication, the fact is that a poor quality oil reduces the durability of an air compressor. If oil greases the system components ineffectively, it can cause the formation of sediment in oil circuits and over the moving parts. Such developments increase the risk of oil oxidation and corrosion of metal parts in the compressed air system. 

Using genuine oil or lubricating fluid offered by your air compressor supplier can ensure effective lubrication, prevent equipment breakdown and derive better performance from your rotary screw air compressor.  

Authentic air compressor oil combines the finest quality of case oil with required amounts of additives that make the product suitable for lubricating an industrial compressed air system.  It is viscous at low temperatures and has high oxidation resistance. 

With a genuine lubricating oil, you will need to top-up less frequently, have lower disposal cost, require less maintenance and face lesser downtime incidents.  

Important points for you to take note: 

Besides procuring spare parts and consumable fluids from OEMs and recognised suppliers, it is also critical to have a proper service kit comprising the hand tools for safe replacement of parts, and for best results, you should get your compressed air system serviced only by experienced repair personnel.  

ELGi offers a range of industrial-grade air compressors for reliable functioning. We also provide bona fide spares that maximise the uptime of your air compressor system and reduce operating costs. With our Annual Maintenance Contract (AMC), you get the assurance of always getting compatible and long-lasting parts along with on-time service by professionals. To know more about our solutions, visit https://www.elgi.com/in/services-parts/ 

Take a look at the key points to focus on a compressor’s installation. 

It is a proven fact that about 70% of an air compressor’s lifetime cost comes from power consumption, which then increases your overall power consumption However, due to the effectiveness and capacity of production support extended by compressed air systems, that it is now an indispensable part of the factory setup, especially in the case of sensitive industries including healthcare, pharma, food & beverage, etc.

Many opportunities exist to reduce the energy used by compressed air systems, beginning with air assessment and air audit. Here are 10 expert tips to help you keep a tab on your electricity bill.

1. LOWER THE PRESSURE: We all know that working under pressure can be hard. Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system caused due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.
2. CHANGE FILTERS ON TIME: While replacing air filters, it is mandatory to maintain the quality of air, it is also an energy-saving opportunity. Delaying an air filter change may cost you a lot. Clogged filters can lead to pressure drops and also hamper efficiency. Ensure on-time service for a healthy compressed air system.
3. INVEST IN PRE-FILTERS: Not only do pre-filters (also known as coalescing filters) help purify the air by removing oil and water, but they also help remove the particulate matter to a certain extent. Installing pre-filters for suctioning the air, and for its cooling, can extend the life of your compressor and its consumables.
4. CLEAN UP: Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. The presence of sludge, dust, or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low-pressure air compressor, and airline for cleaning, to save power.
5. PICK THE RIGHT DRYER: Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.

Hence, one of the first measures you can take to reduce compressed air energy costs is to measure and monitor your energy consumption regularly to optimize usage.