ELGi’s Oil-Free Air Expert addresses query frequently asked by users from various industries. 

Q1. I am setting up a new pharmaceutical bulk drug manufacturing plant. Which compressor should I select? 

The quality of compressed air is critical in applications where the air comes in direct contact with the end product. It should not contain contaminants like oil particles. One more requirement of the pharma segment is uninterrupted operation. Hence, the most suitable solution will be an Oil-Free screw air compressor which is best suited for continuous duty application and delivers compressed air, free from oil contaminants. 

Q2. How is an Oil-Free compressor different from a lubricated compressor? 

In the lubricated compressor, oil is injected into the compression chamber, also called the Airend, during the compression process. This lubricating oil mixes with air, and this Air-Oil mixture is further treated. 

Whereas in an Oil-Free compressor, during compression, there is no injection of oil into the Airend.  Hence, the compressed air does not contain any traces of oil. 

Additionally, Oil-Free air compressors are also eco-friendly since there is no oil spillage from the compressor drain or oil carryover in compressed air. 

Q3.I have fluctuating airflow demand. How can I reduce my operating cost? 

While some setups have a fixed airflow requirement, many factories might be experiencing fluctuating demand. This situation allows us to reduce our operating costs significantly. 

As a best practice, if your airflow demand is not constant, we recommend installing a VFD-equipped air compressor. If you have a fixed air compressor installed already, you can opt for a Retrofit VFD kit matched to your compressor power, which can help regulate the airflow as per plant requirements and reduce power costs. 

Q4. What are the different cooling methods used in Oil-Free air compressors? 

Electrical energy is converted into thermal energy during the compression process. Cooling systems are designed to maintain the system temperature within acceptable limits. 

ELGi offers Oil-Free air compressors in both Air-cooled & Water-cooled variants. 

Q5. My application is critical. How can I be sure that the compressor delivers Oil-Free air all the time? 

The compression process occurs in the compressor chamber called the Airend. An Airend has two sides, the airside and the oil side, which are completely isolated by air & oil seals, which prevent oil from mixing with air. 

ELGi Airends have an additional safety arrangement, wherein even if the seals, for some reason, malfunction, the oil will go back into the sump and not mix with air. Thereby always guaranteeing 100% Oil-Free compressed air. 

Q6.  What all industries use Oil-Free compressors? 

Specific industries require air that directly contacts the end product or is used for sophisticated machines. The presence of oil traces in such scenarios is highly undesirable. 

ELGi offers 100% Oil-Free compressed air solutions to Pharmaceuticals, Food & Beverage, Textile, Automobile, Electronics, FMCG, Oil & Gas, Power, and many more. 

Q7. How does ELGi ensure the high quality of its air compressors? 

Air compressors from ELGi are designed to offer the highest product quality & system reliability to our customers. 

We are one of the very few manufacturers in the world who have their Airend design and build them entirely in-house. 

 Another example of our efforts to go the extra mile is our state-of-the-art foundry set-up to achieve the highest quality in casting. 

Q8. How do I select a suitable air compressor for my application? 

Air compressor selection depends on several factors. A few questions to ask before finalizing one for yourself are – 

– What is the airflow or SCFM required by your pneumatic machines? 

– What is the operating pressure? 

– Does your application need Oil-Free air? 

– Is your airflow demand fluctuating?  

With so many factors to consider, the selection process might seem overwhelming. ELGi offers a wide range of air compressors – Oil-Free and lubricated piston and screw air compressors.  

ELGi’s compressed air experts can help you identify the right solution for your application. We also conduct extensive air audits to map airflow demand accurately to get the most efficient solution. 

To know more, click here.

“The whole purpose of education is to turn mirrors into windows.”

– Sydney J. Harris

Situated in Singarampalayam, India, the ELGi Vocational Training School is a training centre that serves as a perfect example of skill development. The institution strives to provide holistic development to young students from underprivileged backgrounds, by equipping them with technical training and on-the-job skillset.

At the centre, the students receive technical training. Daily, through a practical-based approach, they get to learn basic engineering concepts and production technologies. This is augmented by the centre’s facilities, such as the multimedia classrooms and training spaces for fitting shop, machining, welding, and electrical work.

Apart from this, they also get access to yoga centres and sports facilities, which is instrumental for their physical and mental wellbeing.

For the duration of their course, the students are provided with free boarding and receive a monthly stipend, which helps them provide critical financial support to their families.

Today, let us take a look at the stories of four of our students, whose professional careers have been deeply enriched by the EVTS experience.

There are several parameters to keep in mind while buying an air compressor. Apart from deciding the size, rating expressed in CFM (for airflow), and bar (for air pressure), you also have to choose between an oil-free and oil-lubricated system.

The choice depends on the kind of applications where you intend to operate your air compressor. This is why, it is good to understand how these compressed air systems work and the applications that they’re used for.

Their distinct features can be understood in terms of:

With this backdrop, read about the story of Brieana Lingao, HR Administrator – ELGi USA, on the importance of innovation and hard work for a young professional. 

As per industry reports, India is expected to become the world’s 3rd largest construction market by 2022. Furthermore, increasing the development of the National Highways and initiatives like “Smart City Mission” provide attractive opportunities and drives the growth of this sector.

Concrete batching plants have become an essential machinery and we can’t imagine any construction site without it. In the construction industry, producing high quality concrete in the right amount and delivering it on time is a challenging task. The right quality of concrete increases the reliability of any construction and this is being achieved with concrete batching plants.

Have we ever thought what is driving the concrete batching plants to deliver the right quality concrete on time? Yes, it’s compressed air!

Let us understand the concrete batching plant briefly before going into the usage of compressed air in its operation.

You would find literally everything you need or did not know you needed at a supermarket. Choices of brands, products, sizes, weights, you name it! And while you find yourself spoilt for choice, there is one thing common with all these offerings and that is the packaging. Each of these products is ready and safe for use because of compressed air.

Compressed Air in Packaging Industry

As online shopping continues to rise, the packaging sector sees an expansion in its industry. Compressed air assumes a pivotal role in the manufacturing and packaging operations across various global sectors. Its applications span from cleansing, aligning, shaping, to sealing a wide array of packaging items.

Compressed Air in Food Industry

Last year, the global food packaging market crossed over US$ 302 billion in market value. Compressed air plays a vital role in safely transporting food items and other products around the factory or to their desired location, without any contamination or deterioration in quality. Compressed air is used to shape and seal cartons and boxes, manufacturing products like PET bottles and thoroughly clean all containers before they can be filled with liquids.

Oil-free compressors are indispensable in the food and beverage industry, ensuring product safety and quality by delivering contaminant-free compressed air. They are utilized for tasks like pneumatic conveying, bottling, and packaging, where maintaining a pristine and hygienic production environment is paramount.

Use of Compressed Air in Pharmaceutical Industry

In the pharma industry, oil-free compresses are used to manufacture products including pills and tablets. These tablets or pills are then safely placed in bottles, after the moisture has been removed, and then sealed airtight- maintaining the highest level of clean and sterile compressed air.

Please know more about the significance of oil free air in pharmaceutical industry.

Impact of faulty component selection

A faulty layout, design, and selection of pipe material will cut down profits by:
⦁ Increasing the energy consumed in your air compressor
⦁ Resulting in the failure of the equipment
⦁ Reducing production efficiency
⦁ Increasing maintenance costs

What should be the key focus points in a pipe layout and design?

Fixing leaks is the first thought that pops up in your head! But there is a lot more to your compressed air system.
Here is a list of additional components to be considered for efficient transmission and better quality of compressed air:

1. Air-receiver – It is the primary storage for compressed air to balance the output pressure and application need. The selection of an air-receiver is crucial to meet the demands of the plant, along with the effective operation of the compressor (load / unload).

2. Size – Appropriate selection of the size of the pipe, based on CFM of the compressor, will minimize the pressure drop, thereby reducing energy consumption. The larger the size of the pipe, the lower is the pressure drop.

3. Bends – A straight path for the air is the most efficient. When it comes to bends, a large radius bend is the most preferred. It reduces turbulence, thereby reducing the pressure drop. Note: Avoid short bends as much as possible.

4. Drop-line – Drop line tapping should always be from the top of the main header line, curved down to the application point.

5. Moisture drain points – Moisture drain points at the right place with Auto drain valve, will drain the water from the system.

6. Closed-loop design – It is the most efficient piping layout. There is no beginning or end for the header line, just a continuous loop.

Planning for the long-term is always crucial for the continuity of your business. Hence, when you follow structure, recommendations and timely upgrades in your expansion plans, you are at a better place, avoiding any expensive modifications.

What compressor piping systems are available for businesses?

⦁ Aluminum pipes – The latest technology, Aluminum, is light-weight, making it easy to handle, and is highly recommended for clean air applications. It is non-corrosive and remains leak-free.
⦁ Galvanized pipes – Galvanized steel pipes are widely used in compressed air systems. However, over time, the galvanizing coating flakes off and affects the application equipment in the line.
⦁ PVC pipes – PVC pipes are commonly used in compressed air systems, mostly because they are readily available, inexpensive, and easy to install.

While businesses focus on optimising production and reducing unnecessary costs, air compressor breakdown due to incorrect start-stop might lead to huge operational losses. Here is the need to work on a business continuity plan capable of handling the fast-moving variables of an outbreak like COVID-19.

As some countries across the world are going into lockdown while others are resuming business activities, it is important to follow few steps to ensure proper shut down and start-up of your air compressor and related accessories.

Re-evaluate your energy cost during operation and invest in energy saving products like ELGi Heat Recovery System.Know More

A customer-centric mindset is becoming increasingly important in today’s age of the customer, when organizations are undergoing a digital transformation to manage customer experience and corporate positioning.

By gathering customer insights from multiple sources, organizations can identify their most valuable customers, build nurturing relationships with them and ensure profits for the future.