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How to Reduce Pressure Drop in Compressed Air Lines

Author Archives: Energy Machinery, Inc.

  1. How to Reduce Pressure Drop in Compressed Air Lines

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    Many industrial applications depend on compressed air, but it can be difficult to maintain the efficiency of the compressed air system and minimize pressure drop. 

    A pressure drop occurs when the pressure of the compressed air decreases as it moves through the air system. It can result in equipment damage, increased energy consumption, and poor productivity. 

    Here, we will explore the common causes of pressure drop and how to reduce it for efficient air compressor operation.

     

    Understanding Pressure Drop in Compressed Air Lines

    To effectively reduce pressure drop, it is critical to know the factors that cause it in the first place. 

    Pressure drop is defined as the difference between the air pressure discharged by the compressor and the actual pressure output at the point of use. 

    The following factors influence pressure drop:

    • Friction: Friction between the compressed air and piping causes loss of pressure.
    • Obstructions: Clogs, debris, sharp bends, or other obstructions restrict the flow of air through piping systems, resulting in pressure drop.
    • Pipe Length and Diameter: The diameter and length of pipes within a compressed air system can result in resistance to the airflow, causing a loss of pressure.
    • Fittings and Valves: Imprudent use of valves and fittings can also result in pressure drop.

     

    Calculating Pressure Drop in Compressed Air Lines

    Effectively reducing pressure drop requires an accurate calculation to identify pressure drop in compressed air lines. You can calculate pressure drop using this formula:

    • dp = 7.57q1.85L 104 / (d5p)

    In this formula, dp represents the pressure drop in kg/cm2, q is the airflow volume at atmospheric pressure (m3/min), L is the pipe length in meters, d is the inner diameter of the pipe in millimeters, and p is the rated initial absolute pressure in the system in kg/cm2. An online calculator can also provide fast and accurate results. Identifying pressure drop will allow you to determine the necessary steps to address your system’s pressure issues.

     

    Tips for Reducing Pressure Drop in Compressed Air Lines

    The following tips will help you reduce pressure drops in compressed air lines:

    • Properly Sized Pipes and Components: Selecting the appropriate pipe diameter will reduce the friction within the compressed air lines. Reducing excessive fittings and valves can also reduce system obstructions.
    • Efficient Design and Layout: Choose efficient design options, reduce the length of pipelines, and avoid sharp bends that can cause restrictions. Having an efficient layout can help minimize pressure drop.
    • Air Quality and Moisture Control: Proper filtration can remove particles and contaminants from the compressed air lines. Controlling condensation and humidity can also assist in maintaining consistent air pressure.
    • Energy-Efficient Practices: Optimize compressed air usage using pressure regulation and variable frequency drives (VFDs) to reduce energy consumption and pressure drop.
    • Best Practices for Specific Applications: There is no perfect solution to reduce pressure drop in every industry and application. Implement the most ideal practices for your specific application.

     

    Learn How to Reduce Pressure Drop With Energy Machinery

    Reducing pressure drop is crucial to maintaining the energy efficiency, lifespan, and performance of your compressed air system. Understanding pressure drop and how to calculate it will help you address pressure drop in your system and provide a strategy to minimize it. 

    Consider the length and diameter of pipes and components in your system, minimize valves and fittings, and reduce excessive bends in the pipework to increase the efficiency and performance of your compressed air system. Preventing moisture and contaminants from entering your compressed air system and using VFDs or pressure regulation can also improve your compressor performance and efficiency.

    Since 1971, Energy Machinery has been supplying and servicing compressed air equipment. We work with leading brands, including Zeks, Airtek, Champion, and Gardner Denver, to provide high-quality air compressor equipment and 24/7 emergency service to our customers throughout New England. Our 22,000-square-foot facility is stocked with quality spare parts of all major makes and models. 

    Our team here at Energy Machinery can assist in identifying and resolving your pressure drop issues. Contact us or request a quote for your compressed air needs.

  2. Cycling Refrigerated Air Dryer Vs. Non-Cycling

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    Compressed air is critical in numerous industrial processes, and maintaining its quality is paramount in ensuring optimal system performance. Refrigerated compressed air dryers play a crucial role in compressed air quality by removing contaminants and moisture. However, it’s important to choose the right type of refrigerated air dryer: cycling or non-cycling. 

    Here, you’ll learn more about cycling and non-cycling refrigerated air dryers, including their unique benefits and characteristics, to help you make the right choice for your application.

     

    Cycling Refrigerated Air Dryer Vs. Non-Cycling: Understanding Compressed Air

    Click to ExpandCycling vs. Non-Cycling Refrigerated Air Dryers

    Although compressed air is essential for various applications, it can contain contaminants and moisture that can negatively impact equipment performance and product quality. Refrigerated compressed air dryers eliminate these concerns by cooling the air to condense and remove moisture. In doing so, these systems help to prevent corrosion, prolong the longevity of pneumatic equipment, and maintain product integrity.  

    Depending on the specific application, you may want to use either a cycling refrigerated air dryer or a non-cycling model.

    Cycling Refrigerated Air Dryer

    Cycling refrigerated air dryers automatically adjust their cooling capacity based on the varying needs of the compressed air system. This level of adaptability results in enhanced energy efficiency and cost savings for applications with fluctuating compressed air demands. However, it’s important to note that these systems often come with higher upfront costs and maintenance requirements compared to non-cycling air dryers.

    Non-Cycling Refrigerated Air Dryer

    Unlike cycling systems, non-cycling refrigerated air dryers maintain a constant cooling capacity regardless of variations in demand. These air dryers are simpler and offer enhanced reliability for applications with consistent air needs; however, they may be less energy-efficient in situations where demands fluctuate. 

    Having a strong understanding of your application’s demand variability is critical in deciding whether a cycling or non-cycling dryer is the best choice for your needs.

     

    Considerations for Choosing Cycling Refrigerated Air Dryer Vs. Non-Cycling

    Various factors will influence your decision between cycling and non-cycling refrigerated compressed air dryers. To ensure you make the right choice for your unique application, be sure to consider the following:

    • Demand fluctuations. If your compressed air system’s demand fluctuates frequently, you may want to opt for a cycling refrigerated air dryer. Conversely, if your demand is constant and rarely changes, a non-cycling model might work better.
    • Energy costs. Cycling refrigerated air dryers only refrigerate as needed based on system demand, which will help cut down on energy expenses. If energy costs aren’t a huge concern, you may benefit from the increased reliability of a non-cycling system.
    • Long-term maintenance requirements. Maintenance is another key factor to consider. Cycling air dryers have more maintenance requirements, whereas non-cycling air dryers are simpler in design and therefore come with reduced maintenance needs.
    • Budget constraints. Due to the higher initial cost of cycling refrigerated compressed air dryers, they may not be the best option if budget is a major concern.

     

    Cycling and Non-Cycling Refrigerated Air Dryers from Energy Machinery

    At Energy Machinery, we carry a number of refrigerated compressed air dryers, including both non-cycling and cycling models:

    Non-Cycling

    Our selection of non-cycling refrigerated air dryers includes:

    Cycling

     

    Choose Energy Machinery

    Based on factors such as demand, energy expenses, maintenance, and initial cost, you can determine which type of refrigerated air dryer is right for your compressed air application. These systems not only help to increase operational efficiency but also ensure product integrity and quality.

    At Energy Machinery, we specialize in compressed air systems and offer a wide selection of cycling and non-cycling refrigerated air dryers. 

    For more information about our products, or for help determining the right solution for your compressed air needs, contact us or request a quote today.

  3. How Air Compressors Are Used in the Pharmaceutical Industry

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    Applications within the pharmaceutical industry rely on extremely clean compressed air that is free of contaminants. Oil-free air compressors help achieve this high level of air purity, making them a popular choice for processes ranging from formulation mixing to pharmaceutical product packaging and more. By ensuring contaminant-free pharmaceutical production, oil-free air compressors reduce rejection rates, enhance product quality, and help maintain regulatory compliance. Here, we will discuss oil-free air compressors as well as their many applications within the pharmaceutical industry.

    Click to ExpandHow Air Compressors Are Used in the Pharmaceutical Industry

    What Is an Oil-Free Air Compressor?

    Compared to standard air compressors, oil-free air compressors rely on alternative sealing, cooling, and lubrication techniques, such as intercoolers and water lubrication. While some oil-free air compressors contain oil, the oil does not come in contact with the compressor, delivering higher-quality, contaminant-free air for manufacturing processes. This is especially crucial in preventing damage to products and equipment components.

    Common Air Compressor Applications in the Pharmaceutical Industry

    Oil-free air compressors are used in the pharmaceutical industry for various applications, including mixing formulations at specified quanitites, forming and coating tablets, capsule packaging, and more. They are also used to power pneumatic tools used to precisely mix ingredients for drops, syrups, and other medicines. By utilizing oil-free air, manufacturers ensure contaminant-free end products that are safe for consumption.

    Other applications of oil-free air compressors within the pharmaceutical industry include:

    • Bottling/Canning/Packaging. Oil-free compressed air can clean and dry bottles, cans, and other pharmaceutical packaging materials. Because the air makes direct contact with the product, it must be Class 0 oil-free air to avoid contamination.
    • Capsule & Tablet Manufacturing. Almost every part of the tablet and capsule manufacturing process requires compressed air, from packaging and coating to drying, processing, mixing, and granulation. Each step requires class 0 air to prevent contamination.
    • Production of Ointments, Gels, Creams & Syrups. Before filling tubes or vials with a pharmaceutical product, oil-free compressed air is used to remove dust and moisture from the container without the risk of contamination.
    • Fermentation. Fermenters require aeration from sterile, non-contaminated air to prevent the bacteria from being polluted. This ensures a high-quality end product.
    • Instrumentation Air. During pharmaceutical production, pneumatic conveying relies on clean, contaminant-free air to move the product. Aside from conveying, oil-free compressed air is used for polishing, sorting, valve control, and more.
    • Wastewater Treatment. Water used in pharmaceutical production must be treated to prevent contamination. After use, water must be treated again before reuse or disposal.

    Choose Energy Machinery for Your Oil-Free Air Compressors

    Oil-free air compressors play a vital role in the production of pharmaceutical products, providing a clean source of air for various applications. At Energy Machinery, we offer comprehensive air compressor services, parts, and rentals. With over five decades of experience, we have the necessary expertise and capabilities to deliver oil-free air compressor solutions that meet your application’s requirements.

    Our team provides 24/7 field service as well as planned maintenance programs, troubleshooting, repairs, and turnkey installations for compressors, blowers, pumps, dryers, and related accessories. Energy Machinery is an authorized warranty repair center for some of the most well-known compressor manufacturers, and our fleet of short-term rentals include numerous compressors and dryers to suit customer needs.

    For more information about how our oil-free air compressor solutions can benefit the pharmaceutical industry, contact us or request information today.

  4. All About Medical Air Compressors

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    Click to ExpandAll About Medical Air Compressor

    Of the air compressor types available for various applications, medical air compressors fulfill the compressed air needs of the healthcare sector. As such, they require high-precision construction and must meet stringent safety standards for medical facility use. Read on to learn more about these compressors, oil-free compressor types, and their vital applications in the medical field.

    What Is a Medical Air Compressor?

    A medical air compressor is a component within a pipe system that supplies dry, clean, and odorless compressed air for a healthcare facility. These devices work by taking high amounts of air and forcing it into a storage tank. As the pressure within that tank grows, it ultimately produces the kinetic energy that a compressor uses to serve its purpose.

    Compressed air assists healthcare providers with optimal air quality, power generation, and sterilization. Oil-free air compressors can successfully maintain a controlled flow of uncontaminated air, reduce exposure to high oxygen concentrations or gas contamination, and serve as an anesthetic agent carrier gas. These versatile units also drive both incubators and ventilators, and can power operating room tools.

    Types of Medical Air Compressors

    There are several varieties of medical oil-free air compressors available to fit the needs of your healthcare application.

    Oil-Free Scroll Compressors
    These medical air compressors have virtually zero air contamination risk for patients. Scroll compressors don’t experience overheating, and they have the added benefits of being low maintenance with minimal noise generation.

    Oil-Free Screw Compressors
    This type of medical compressor usually has applications in manufacturing devices for the healthcare sector. They’re particularly efficient for lesser energy consumption, and they generate little noise. Screw compressors are also useful for medical patients since they, like oil-free scroll compressors, pose no chance of air contamination.

    Oil-Less Reciprocating Compressors
    These cost-effective air compressors don’t require lubrication to function, resulting in no air contamination. There can be overheating concerns with this type of compressor; however, the solution to this is simply to incorporate a cooler into your system. Reciprocating compressors require regular maintenance on components like belts and pistons to avoid malfunctioning, but properly maintained, they’re a flexible compressor option.

    What Are the Applications of Medical Air Compressors?

    Oil-free air compressors perform numerous critical applications in the healthcare sector, including:

    • Assisting patients in breathing. Hospitals and other healthcare facilities set up medical air compressors to provide clean, reliably uncontaminated air to patients having difficulty breathing or those who are under sedation or anesthesia.
    • Sterilizing. In the medical field, cleanliness is of particular importance. Compressed air is useful for sterilization applications, such as power-cleaning equipment or working as part of a sterilization system.
    • Powering surgical devices. Medical air compressors can effectively provide power for hand-held surgical tools in applications like drilling and puncturing.
    • Fulfilling laboratory functions. Medical laboratories utilize compressors to power x-ray, mammogram, oxygen and nitrogen generation, and blood analyzing equipment, as well as chiropractic tables.

    Medical Air Compressors From Energy Machinery, Inc.

    Medical air compressors are crucial components in healthcare and pharmaceutical settings. They ensure that patients have clean, pure air to breathe while powering and sterilizing important medical devices. As New England’s compressed air experts since 1971, Energy Machinery specializes in air compressors for a range of diverse industries. We offer well-known brands with proven products, such as Airtek, Bauer, Champion, Gardner Denver, SPX Hankison, and Zeks, to support all our clients with high-quality compressed air equipment.

    We strive to provide comprehensive services on all air compressor makes and models, which is why our factory-certified technicians provide turnkey installations and 24-hour field service for scheduled maintenance and unexpected repairs. Energy Machinery also maintains an extensive inventory of components for current and older compressor models in our 22,000-sq.-ft. facility in Rockland, Massachusetts. We even provide short-term rentals to support you, no matter your needs.

    To learn how medical air compressors can assist your facility, contact us today and request more information.

  5. Different Types of Reciprocating Compressors

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    Reciprocating compressors are positive-displacement machines that compress and deliver gases at high pressures through the use of a piston or plunger. Refineries, gas transmission pipelines, and many other applications use reciprocating compressors to transfer hydrogen, oxygen, and other gases. This type of compressor is often used when the process fluid is relatively dry and when high compression ratios are required per stage without high flow rates.

    In this post, we’ll review the different types of reciprocating compressors and some of the reliable options available from Energy Machinery, Inc.

    Oil-Free vs Lubricated Reciprocating Compressors

    Click to Expanddifferent types of reciprocating compressors

    Applications can use either lubricated or oil-less reciprocating compressors based on their unique requirements.

    Lubricated Reciprocating Compressors
    Lubricated reciprocating compressors use lubricating oil to keep the piston running smoothly without causing damage to the mechanism. The lubricant also serves to maintain air compression efficiency and dissipate heat. This type of reciprocating compressor requires more frequent maintenance checks as well as periodic oil changes. Additionally, they require added air filtration, including coalescing filters and separators, which prevent oil from contaminating processes and affecting downstream equipment.

    Oil-Free Reciprocating Compressors
    With oil-free reciprocating compressors, the compression element is coated with a pre-lubricating material, eliminating the need for oil-based or synthetic lubrication. This type of compressor requires less routine maintenance but more extensive repairs. They also have a much shorter lifespan and they’re considerably louder during operation.

    Because of these differences, lubricated reciprocating compressors are often more ideal for applications where compressors will experience heavy use. However, food processing, pharmaceutical, and other applications may want to use an oil-less compressor if they require air with high purity levels.

    Types of Reciprocating Compressors

    Whether you require oil-less or lubricated reciprocating compressors for your application, Energy Machinery, Inc. carries a variety of models to meet your needs. Our line of compressors includes:

    • PureAir Oil-Less Compressor. The Gardner Denver PureAir Series compressors are electric motor driven and designed to meet strict specifications regarding air purity for both institutional and industrial applications.
    • PureAir II Oil-Less Compressor. This Gardner Denver compressor is capable of 24-hour operation, which prevents the need for backup units and oversizing for optimal cost-effectiveness.
    • Reward Series™ – Reciprocating Air Compressors. Gardner Denver’s Reward Series compressors feature long-lasting designs that make them ideal for any application. Each compressor also includes as many as six standard pre-installed accessories.
    • R-Series Splash-Lubricated Compressor. R-Series compressors include a variety of unique features such as automotive-type domed pistons, which allow for the use of large-diameter, low-lift valves while providing maximum air delivery.
    • PL-Series Pressure-Lubricated Compressor. PL-Series compressors, much like the R-Series, include automotive-type domed pistons and other features for top performance. This model is specifically designed for use in extreme-duty applications, serving as an alternative for R-Series models.
    • Paradigm – Low Noise Reciprocating Air Compressors. These compressors are ideal for applications requiring quiet operation.
    • A-Series Reciprocating Compressors, Vacuum Pumps, and Boosters for Air and Natural Gas. A-Series compressors offer unbeatable accessibility, reliability, and quality with each component.
    • Climate Control Air-Cooled Reciprocating Compressors. Gardner Denver’s climate control compressors can meet the needs of nearly any application with complex climate control systems.
    • R and PL-Series Lubricated Air Compressors and Bare Pumps. Gardner Denver’s R and PL-Series compressors and bare pumps offer superior quality, longevity, and efficiency.

    Reciprocating Compressors Serving New England

    Oil-free and lubricated reciprocating compressors can meet the needs of many applications across a wide range of industries. To make sure you find the equipment that’s right for you, turn to the experts at Energy Machinery, Inc. We can help you locate the ideal solution in our extensive line of top-quality products. For more information about our reciprocating compressors or to get started with the selection process, contact us today.

  6. What Is a Compressor?

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    Many industrial processes rely on compressors to increase the pressure of a gas by reducing its volume. Industries such as HVAC, oil & gas, and more rely on compressors for everyday operations. Compressors work by forcing gas into the chamber where it is pressurized. From there, the pressurized gas is released so it can power various equipment and processes. Here, we will discuss the differences between oil and oil-free compressors as well as the various types of compressors available at Energy Machinery, Inc.

    Oil vs. Oil-Free Compressors

    Oil and oil-free gas compressors both deliver compressed, high-pressure gases that can be used in a wide variety of pneumatic applications. However, there are several key differences between these two categories. Oil compressors use oil-based lubricants to smooth the movement of internal components so there’s less wear, heat buildup, and noise during operations. Oil-free compressors are pre-lubricated by manufacturers and do not require lubrication throughout their lifespans.

    Other important differences include:

    • Maintenance Requirements. Oil compressors require routine maintenance and frequent oil changes, whereas oil-free compressors are maintenance-free.
    • Lifespan. Oil compressors last longer than oil-free alternatives (provided they have proper maintenance). They are more rugged, more durable, and less likely to break down due to wear and heat buildup.
    • Mobility. Oil-free compressors are lighter and more portable, whereas oil compressors are heavier and not as mobile.
    • Price. Oil-free compressors are cheaper per unit than oil compressors. They are also cheaper due to not needing frequent applications of oil lubricant. However, the increased lifespan of oil compressors can lead to overall savings depending on how often the unit is used.

    Different Types of Compressors

    There are many different types of compressors to suit the needs of various industries and applications. At Energy Machinery, Inc., we offer the following compressor types:

    What is a Compressor

    Click to Enlarge

    • Reciprocating Compressors:
      • Reciprocating compressors, or piston compressors, are positive displacement machines that rely on the reciprocating action of two or more pistons to compress gas and deliver it at high pressure. The gas is compressed within a cylinder and discharged through valves into receiving tanks. Common applications for reciprocating compressors include gas transmission pipelines, refineries, and more.
    • Rotary Screw, Scroll, and Vane Compressors:
      • Rotary screw compressors use two meshed rotors to pull in gas. The gas is then compressed as it moves down through the rotors before it is discharged through a discharge port. This type of compressor offers quiet operation compared to reciprocating compressors and is ideal for construction and road building applications.Scroll compressors feature orbiting and stationary spirals which work to decrease the volume of space between them as the orbiting spirals move along the path of the stationary spirals. The gas enters at the outer edge of the scrolls and discharge takes place near the center. This type of compressor is commonly used for home air-conditioning and low-end applications.Vane compressors rely on a series of vanes that rotate from the suction side to the discharge side of an eccentric cavity. As the vanes sweep along the wall, they reduce the volume of space, compressing the gas trapped within. These compressors are commonly used in oil & gas and other process industries.
    • Variable Speed Compressors:
      • These units are rotary screw air compressors with variable speed drives that control the motion of the pieces. This type of compressor is very energy-efficient and can change to meet the needs of fluctuating demands.
    • Oil-Free Compressors:
      • Oil-free compressors do not rely on lubricating oil, making them ideal for applications where contamination is a concern, such as food processing, pharmaceuticals, and more. We offer a range of oil-free compressors, including rotary screw and two stage variable speed centrifugal variations.

    Providing Quality Air Compressors to New England

    Compressors are available in many types to suit the requirements of various industries and applications. Since 1971, Energy Machinery, Inc. has provided high-quality compressed air equipment to our customers. To learn more about our products, or for help selecting the best compressor option for your needs, contact us today.

  7. All About Oil-Free Air Compressors

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    Air compressors take in air and pressurize it, creating clean, compressed air that plays a vital role in industries such as textiles, electronics, food, automotive, and packaging. Air compressors are at most job sites given their varied applications. There are different types of air compressors that you can purchase for industrial use, and they vary in weight, size, output performance, and overall benefits. Knowing the distinctions between oil-free and oil air compressors will help you pick the right type for your project.

    What Is an Oil-Free Air Compressor?

    Click to Expand oil-free air compressors

    Oil-free compressors use alternative lubrication, cooling, and sealing methods, such as water lubrication, pre-lubricated cylinders, and intercoolers. Although some of these compressors do technically contain oil, the oil can’t come into contact with the compressor, which eliminates the risk associated with oil contamination and provides high-quality air for manufacturing. Air contamination from oil could harm equipment components or damage a company’s manufactured products.

    Some of the industries that use oil-free air compressors and benefit from the lack of contamination risk include:

    • Pharmaceuticals
    • Paper
    • Power generation
    • Medical
    • Chemical
    • Food and beverage

    Oil-Free Air Compressor Benefits

    The advantages of using oil-free compressors include:

    • Portability. Most of these compressors are portable and have a compact design.
    • Weight. Oil-free compressors are lighter, so you can carry them easily during different commercial applications.
    • Noise reduction. The modern oil compressors are quieter than traditional ones due to the dual-piston, direct drive, and sound-reducing technology.
    • Cleanliness. Oil-free compressors are preferable in cleaner applications such as food and beverage processing because they produce quality air without contamination risks.
    • Lower maintenance and cost. With lower energy usage and fewer maintenance concerns handling leaks, oily condensate, and separator and filter replacement components, oil-free compressors can be a cost-effective solution.
    • Lubrication. You don’t have to lubricate this equipment manually.
    • Environmental concerns. These compressors reduce environmental impacts and toxic emissions since oil-free compressors do not need scheduled oil changes.
    • Safety. Oil-free compressors limit the likelihood of compressed air pipeline fires resulting from oil carryover.

    Oil-Free Air Compressors vs. Oil Air Compressors

    Oil-Free Air Compressors

    One of the most notable features of an oil-free air compressor is the noninteraction between the compressed air and lubrication oil. This results in a better quality air supply, which is valuable in applications such as cleanrooms and dentistry. Also, oil-free compressors weigh much less than oil-lubricated compressors. This makes them ideal for commercial applications in medical air supplies, tire inflation, pneumatic tools, and jackhammering.

    Oil Air Compressors

    In oil-lubricated air compressors, however, the oil running the unit interacts with the output air, potentially introducing contamination. Oil droplets, liquids, mist, and vapors can get into the compressed air. Also, oil air compressors are often mounted as they are heavier and more cumbersome. As a result, they work best in applications that don’t need continual relocation.

    Featured Oil-Free Air Compressors

    Some of the oil-free compressor types available include:

      • PureAir Oil-Less Air Compressors. These compressors have advanced features and meet exacting standards to ensure better air quality. You also enjoy less maintenance and noise as some of the system’s benefits.
      • PureAir II Oil-Less Air Compressors. The PureAir II compressors feature a pressure-based, mounted, oil-less design that is ideal for continuous operation.
      • EnviroAire Series Oil-Free Rotary Screw Compressors. These EnviroAire units are water-injected compressors that operate at a lower temperature, providing low power consumption, high efficiency levels, and near isothermal compression.
      • Ultima Oil-Free Two Stage Variable Speed Compressors. These unique design units have a dry screw air end which provide the ultimate in efficiency.

    Click here to learn more about Gardner Denver’s updated Oil-Free compressor solutions

    Oil-Free Air Compressors From Energy Machinery

    Oil-free compressors are becoming popular in many industries for their various applications and lack of risk for oil contamination. At Energy Machinery, Inc., we have a comprehensive range of oil-free compressors to suit almost any industrial need.

    If you would like to find out more about our line of oil-free compressor solutions, please feel free to view our equipment catalog or contact us today. You can also request information for other products such as reciprocating compressors, variable speed compressors, lubricants and repair parts, used machinery, refrigerated air dryers, and more.

  8. Rotary Screw Air Compressor Guide

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    Air compressors are pneumatic devices that increase the pressure of a gas by compressing it into a smaller volume. The kinetic energy contained in the pressurized air can then be used to power various tools and equipment. Based on their method of operation, air compressors can be split into several categories. The most common types include:

    Rotary Screw Air Compressor Guide

    Click to Enlarge

    • Rotary screw
    • Rotary vane
    • Scroll

    What Is a Rotary Screw Air Compressor?

    Rotary screw air compressors utilize a rotary-type positive displacement mechanism to compress air. Two intertwined screw rotors trap the ambient air and force it through the compression chamber as they rotate. As the air moves toward the discharge valve, its volume gradually decreases while its pressure increases. The resulting compressed air can then be used to operate air-driven tools, inflate tires, or power pneumatic equipment.

    The main components of a rotary screw compressor include:

    • Air-end. This is the part of the compressor where the actual air compression occurs.
    • Air filter. The air filter purifies the air before it enters the compressor.
    • Primary separator tank. This component separates the compressed air from the compressor oil as it exits the air-end.
    • Secondary separation filter. The secondary separation filter collects any remaining oil particles in the air and circulates them back to the main oiling system.
    • Oil filter. The oil filter traps particles or contaminants from the oil before it re-enters the compressor
    • Oil cooler. This component cools the hot oil before it returns to the compressor.
    • Hoses. The hoses facilitate oil and air movement among various compressor components.
    • Controls. Controls operate the air compressor and provide relevant diagnostic or service information.
    • Oil. Oil lubricates the compressor, protects internal components, traps contaminants, and keeps the system cool.

    Rotary Screw Air Compressor Benefits

    Rotary screw air compressors provide the following advantages in compressed air applications:

    • Continuous operation. Operating at 100% duty cycle, rotary screw compressors can function for long periods of time without requiring downtime to cool.
    • Powerful yet quiet performance. Rotary screw compressors can deliver large volumes of air while producing minimal noise.
    • Higher CFM per HP. Compared with reciprocating and piston compressors, rotary screw compressors can move larger quantities of air—measured in cubic feet per minute (CFM)—per horsepower (HP).
    • Superior lifespan and energy efficiency. When maintained properly, rotary screw compressors can last 6-8 times longer than reciprocating or piston-based compressors and tend to have better warranties. They also generate significantly less heat, making them much more energy efficient.

    Rotary Screw Compressors Vs. Rotary Vane Compressors

    While they offer similar benefits, rotary screw and rotary vane compressors each have distinct capabilities that influence their suitability for certain applications. These include:

    • Applications. Rotary vane compressors are ideal when a smaller, quieter unit is preferred, while rotary screw compressors are better suited for larger horsepower applications with higher pressure requirements.
    • Leakage & lubrication. While the rate of leakage in rotary screw compressors tends to increase over time, a rotary vane compressor’s design allows for reduced leakage with increasing use.
    • Speed control. The energy efficiency of a rotary vane compressor is significantly reduced when operating speeds exceed or fall below their functional range. In contrast, rotary screw compressors can quickly adapt to variations in air demand with minor losses in efficiency.
    • Bearings. Compared with the simple bearings used in rotary vane compressors, the complex ball bearings of rotary screw compressors typically require more frequent inspection and replacement.
    • Repair & maintenance costs. In general, rotary screw compressors are more complex in design and require more maintenance and repair than their rotary vane counterparts.

    Featured Rotary Screw Air Compressors

    At Energy Machinery, we provide a variety of rotary screw air compressor options to suit specific applications. These include:

    Rotary Screw Air Compressors from Energy Machinery

    Energy Machinery offers an extensive selection of rotary screw air compressors from Gardner Denver and other leading manufacturers. With five decades of experience in our industry, we have the expertise and product selection to meet your specific needs while adhering to your budget.

    To learn more about our rotary screw air compressors or other products, please contact us today.

     

  9. Silent Air Compressor Buying Guide

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    Traditional air compressors create a great deal of excessive noise, which can cause various issues such as hearing loss, communication errors, decreased productivity, and more. To prevent these issues, many facilities invest in silent air compressors, which are specifically engineered to emit low levels of noise. The noise dampening properties of silent air compressors helps to decrease mechanical sound and noise pollution while still providing the compressed air needed for your operations.

    Silent Air Compressors Overview

    Click to Expandsilent air compressor buying guide

    Air compressor manufacturers recognize the potential for injury caused by high-volume compressors, which is why they have established standardized ratings based on decibel (dB) levels. The three standard ratings for air compressors are:

    • 40 dB. This compressor rating produces the lowest level of noise. Smaller, low-power air compressors tend to fall within this category.
    • 60 dB. This compressor rating is recognized as the safest noise level for air compressors.
    • 85 dB. Compressors with this rating regularly produce sound that exceeds safe noise levels. Employees who are exposed to this level of sound on a regular basis may experience negative health effects.

    Silent air compressors are specifically designed to create minimal noise through the use of advanced sound-reduction technology. They operate at or below 75 dB. Heavy hardware and noise-dampening materials minimize vibration, and a portable noise-dampening cover further eliminates excess sound. Silent air compressors come in oil-lubricated and oil-free designs, each of which features smooth component motion that reduces excess vibration from friction, grinding, and wear.

    Silent Air Compressors Advantages

    Silent air compressors offer a variety of advantages over more traditional compressor designs, including:

    • Reduced Maintenance
    • Lower Operating Costs
    • Many Applications
    • Extremely Portable
    • Reduced Power Consumption
    • Simple Start-Up
    • Low-Maintenance and Repair Costs
    • Improved Worker Safety

    Silent Air Compressors Applications

    Silent air compressors provide safe, efficient compressed air for a wide range of applications, including:

    • Spray Painting and Coating Equipment
    • Air-Powered and Air Impact Tools
    • Pneumatic Lifts and Elevators
    • Shot Peening and Sandblasting
    • Heating and Cooling Operations
    • Power Cleaning

    Featured Silent Air Compressors

    Energy Machinery, Inc. is pleased to offer a full selection of silent air compressors for use in a variety of domestic, commercial, and industrial applications. All of our ESM 6 compressors are highly efficient, extremely quiet, and cost-effective to operate and maintain.

    ESM 6 – Standard Compressor
    Our ESM 6 Standard Compressor is specifically designed for simplicity and ease of use. This compact 680 mm screw compressor is available with pressures up to 8 bar (115 psig). For those looking for a complete compressor station, we can customize your ESM 6 with tank-mounting and refrigerant dryer plus filter kit options. Installation and maintenance are simple, with removable side doors and quick access to all service points.

    ESM 6 – Mounted on 270 L Receiver
    This ESM 6 compressor is mounted on a 270 L receiver, which increases pressure up to 10 bar (145 psig). Larger than the standard, this model is 1540 mm wide and can be customized with an add-on refrigerant dryer and filter kit. Ideal for moderate commercial and industrial applications, the ESM 6 mounted on 270 L receiver is simple to install and maintain, with easy-to-adjust pressure settings.

    ESM 6 – Mounted on 500 L Receiver
    Our highest capacity ESM 6 design, mounted on 500 L receiver, provides pressures up to 13 bar (190 psig) in a package that is 1950 mm wide. This tank-mounted version can be customized with a refrigerant dryer and filter kit. This design is perfect for larger operations, with ample pressure for commercial and industrial washing, coating, painting, and cleaning operations.

    Silent Air Compressors from Energy Machinery, Inc.

    At Energy Machinery, Inc., we provide superior compressed air equipment for virtually any operation. To learn more about our selection of silent air compressors, contact us today!

  10. Rotary Vane Compressor

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    Rotary Vane Compressor

    An air compressor converts power from electricity, gas, or other sources into potential energy in the form of pressurized air. The pressurized air can be released in a controlled way to provide the kinetic energy needed for its given application.

    In principle, an air compressor’s design is relatively straightforward. Air is brought into a chamber by means of intake valves and thereupon pressurized by a reduction in the chamber’s volume. When energy is needed from the compressor, the pressurized air is released via a discharge valve. 

    There are several types of air compressors available on the market today. There are three common types of air compressors: 

    • Rotary screw
    • Scroll
    • Rotary vane

     

    This blog post will mainly focus on the design and advantages provided by rotary vane compressors. 

    What is a Rotary Vane Compressor?

    Rotary vane air compressors use centrifugal motion to pressurize the air. They are thus designed quite differently from compressors with reciprocating pistons—instead of utilizing a pumping motion to compress air, rotary vane machines employ a spinning technique.

    How Does a Rotary Vane Compressor Work?

    All rotary vane compressors come equipped with a cylindrical rotor that is off-center from its housing. This rotor contains several partitions—or walls— that extend outwards towards the housing.

    As air is drawn into the housing chamber via intake valves, the rotor spins around in a circular motion. As the rotor spins, its walls squeeze the air trapped between the rotor and the edge of the housing into progressively smaller spaces, which is why the rotor is offset from the center of the housing. This quickly pressurizes the air.

    The now-pressurized air is funneled towards a discharge valve where it may be released and used by a manual operator or automated process. The rotor continues spinning, and the cycle repeats to maintain a steady flow of pressurized air. 

    Advantages of a Rotary Vane Compressor

    There are several advantages provided by rotary vane air compressors, such as:

    • Efficiency. Rotary vane compressors are highly energy-efficient, with their rotors typically spinning at 1,800 rpm or less.
    •  Longevity. Rotary vane compressors are very durable, with some rated for more than 100,000 hours of optimal service.
    •  Flexibility. Rotary vane compressors are extremely versatile, serving a diverse range of industries and applications.

    Rotary Vane Compressors vs. Rotary Screw Compressors

    Rotary vane compressors are often compared to their closest counterpart, the rotary screw compressor. Each compressor has unique advantages and drawbacks. The following is a brief overview of some key differences between the two machines:

    •  Complexity. Rotary vane compressors are fairly simple machines, both in design and in operation. In contrast, rotary screw compressors are much more complex and sensitive, since they include not one major moving part, but two simultaneously active screws that must perfectly match one another’s movements. 
    • Durability. The rotary vane design is much more durable than the rotary screw, featuring 100,000 hours of service life versus 30,000–40,000 hours for the rotary screw design.
    • Power usage. Rotary screw compressors require continuous turns of 3,000–8,000 rpm, versus 1,800 rpm for rotary vane devices. 
    • Maintenance. Generally speaking, rotary vane compressors require more maintenance than rotary screw machines. For example, many rotary vane compressors require an oil change every 2,000 working hours; this interval between servicing is twice as long for rotary screw machines (about 4,000 working hours).

    Rotary Vane Compressors for Sale

    At Energy Machinery, we offer an extensive catalog of rotary vane compressors from Gardner Denver and other major compressor brands. We have provided world-class products and exceptional customer service to customers in a broad range of industries for almost five decades. 

    If you’d like to learn more about our selection of rotary vane compressors or any other products from our catalog, please contact us.

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About Us

Established in 1971, Energy Machinery, Inc. provides quality compressed air equipment and supports those products with exceptional customer service.

50+ years In business

50+ years In business

Distributor deals with over 20 major manufacturers

Distributor deals with over 20 major manufacturers

24 hour field service from certified technicians

24 hour field service from certified technicians

Learn More About Us
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