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Is your compressed air system complete?
AIR COMPRESSORS
Convert electrical or engine power into compressed air for tools, processes, and systems, available in reciprocating, rotary screw, scroll, and oil-free designs.
WET TANKS
Store compressed air before the dryer to handle short demand spikes. This keeps pressure stable, drops heat and moisture early, and protects downstream equipment.
PRE-FILTERS
A 1-micron pre-filter traps rust, scale, and debris before the dryer, protecting the dryer and downstream filters, maintaining efficiency, and forming the first layer of air-quality control.
AIR DRYERS
Designed to extract water vapor from compressed air streams, preventing corrosion, product contamination, and equipment damage.
AFTER-FILTERS
After the dryer, a .01-micron coalescing stage removes ultrafine oil aerosol and vapor as cooler air condenses droplets, delivering oil-free air for tools/instruments.
AIR TANKS
Add extra compressed air storage to stabilize pressure, handle demand spikes, and reduce compressor wear.
OIL/WATER SEPARATORS
Separate and remove oil from condensate drains to ensure environmental compliance and clean disposal.
Featured Articles
Ideal Compressed Air Piping Layouts
Finding Your Ideal Layout Compressed air piping is a necessary component of any compressed air system, delivering compressed air where it is needed. A significant concern with compressed air piping is designing an ideal layout for your operation. There is no one-size-fits-all system. Your compressed air piping needs to be able to deliver sufficient volume, at a high quality, and with enough pressure to meet your demands. To adequately meet your compressed air requirements, you must consider multiple factors about your piping. The size, material, and distance of your piping influence the quality of compressed air. Individual aspects of your piping lead to different end results. For example, your piping diameter is dependent on your flow rate, pressure, pressure drop, and total length of the system. To determine your desired pipe diameter, you need an idea of how much air you need to transport. Your compressed air piping system is similar to a highway, and your road needs to be the right size to handle all the traffic. If your compressed air system requires large quantities of air to be transported from the compressors to the point of use, you will need larger piping than systems that require less. Just as busier highways are broader and more complex to handle increased traffic, pipe systems with lots of compressed air need larger diameter pipes. Different Layouts for Different Operations Each case is unique when it comes to compressed air piping requirements. A setup that works for your neighbor in the same industry might not work for your facility. The layout of your facility, the distance from the compressor to your point of use, and other variables that are unique to your operation all determine the type and size of your piping. A good starting point for preparing a layout for your compressed air piping system is the pipe size. Next, you can determine how much of that pipe you will need to get the compressed air to the end of the line. Once you know how much piping you need in the larger sizes, work down to smaller pipes for drops. After you have an idea of the quantity of piping you need, you will need the connections and unions to bring the system together. In optimized systems, energy costs will decrease, equipment failure is less likely, and overall production efficiency will improve. Changes in your layout can improve the overall efficiency of your piping system, but that requires knowing how to set it up in the most efficient manner possible. Considerations For Your Piping Layout When designing your compressed air piping, there are a few variables that you need to consider before you settle on the products. Each system will require a different level of pressure and airflow. Airflow is impacted by the size of your piping, the material it is made from, and the turns/angles of the piping. Size of Compressed Air Pipe As we mentioned in our highway metaphor, your compressed air piping needs to be capable of transporting the air without pressure drops or blockage. Incorrectly sized pipe will rapidly increase the degradation process and incur steep maintenance costs. Inadequately sized piping, too large or too small, is detrimental to your process. It can also be affected by the size of your compressor. Your compressor will determine the CFM and PSI of the air being introduced into the system. You could have the correct-sized pipe for your needs; your compressor just might not be up to par. Ensure your compressor and pipe are correctly sized to deliver the right air volume at an acceptable pressure. If they are incorrectly sized, problems can be expected. Piping Material Compressed air piping comes in various materials: stainless steel, black iron, aluminum, copper, and PVC, which should never be used. What material works best for your system depends on your required air quality and the capital available to invest in piping. Each material has its pros and cons, with some having more negatives than positives. Different materials come with unique operational preferences as well. Individuals in your shop may be comfortable with stainless steel piping because that is what your system has used for years. Comfort with a material is a valid reason to keep using it; no need to learn a new piping system. Black iron and copper pipes are industry classics for compressed air piping. They are standards for opposite reasons: copper is corrosion-free and easily adaptable to fit your facility, while black iron is implemented for its strong and durable material. Unlike copper, black iron is heavy and susceptible to corrosion. Both materials have good reasons to use them, but their durability and connections make future changes a nightmare. Aluminum is the cream of the crop in terms of compressed air piping material. Like stainless steel, it is resistant to corrosion and degradation. However, aluminum has the same resistance as stainless steel but at a fraction of the total weight. With similar connections made even easier by “plug and play” components, the skills required for stainless steel piping are the same as those for aluminum piping. Pathway of Pipe High-congestion areas or sharp turns cause pressure drops and turbulence. When airflow slows down, the pressure drops along with the CFM. When a sharp turn is present, the air needs to slow down to make it around the corner, just like it would when driving on a highway. Sharp turns slow down the airflow and increase the amount of turbulence. Turbulence occurs when air is forced to slow down as it flows into a bend. As the air slows down, its path changes. Rather than being uniform with a laminar flow, the layers of air will begin to lose their shape. Turbulence is detrimental to the flow of compressed air and increases the likelihood of equipment failures. When it comes to your compressed air By installing gentler bends, you can minimize the turbulence created. Typically, you should minimize the number of 90-degree turns at junctions and use as many 30-degree to 40-degree turns as possible. When using a 90-degree bend, you can expect turbulence and a pressure drop of 3-5 PSI for every turn. Moisture Content Moisture in compressed air is a natural part of the compression process; however, it will deteriorate your system over time. If too much moisture is present in your piping, the inner lining will begin to corrode. As the material corrodes, particles can flake off and gather together. Buildup of particulate matter can completely obstruct airflow, which is precisely why you have filtration and a dryer in place. If you adequately remove moisture and particulate matter from the air, your odds of this occurring are drastically reduced. If you are worried about excess condensation dropping out of the air, moisture separators being installed along the line or near the point of use can provide an additional layer of moisture removal. Future Opportunities When designing a compressed air piping system, it’s easy to tunnel vision on the present. You want to ensure that your equipment and pipe will deliver the desired quantity of air at the correct pressure. When you are so focused on making sure it works now, planning for the future can fall to the back of your mind. But this is precisely when you want to prepare for the future. With plug-and-play connections, adding on to your system is a piece of cake. When it comes time to expand your operations, you can add to your existing equipment rather than rebuilding it entirely. Keeping future expansions in mind while creating a compressed air piping system will make life easier for your future self. Configuring Your Compressed Air Piping Layout People use a few different variations when setting up their compressed air piping. Each network is a little more complicated than the last, but that just shows how many different ways there are to achieve your desired results. Linear Air Piping System The simplest way to set up your compressed air piping is also the least efficient use of your compressed air. Linear air piping systems are exactly that, a line with a start and an end. The air starts at the compressor and moves through the system until it reaches the line’s end. As the air moves from the air compressor to the end of the line, the compressed air is being used up. The farther down the line it gets, the more compressed air is consumed. As you get to the end of the line, the total air volume is depleted. There is no issue with enough compressed air for the drops in front, but that story quickly changes as you follow the flow. End-of-the-line equipment is left without compressed air, and as long as the equipment is drawing air, the latter equipment will be dealing with leftovers. Antenna Air Piping System A step above your linear air piping system, antenna air piping systems provide a more equal distribution of the compressed air. With a larger main distribution line going down the center and auxiliary branches for individual supply lines. These systems are made even better when compressed air storage is included on both sides of the main header. This keeps the airflow constant throughout the system. Unlike linear systems, no sections are left without compressed air. A shut-off valve can also be attached to each individual branch to isolate the individual branches. When an area no longer needs air, it can be closed off so the excess air can travel to other parts of the system or back to a storage tank. Closed-Loop Air Piping System It is the most common type of compressed air piping system, and for good reason. With a uniform distribution of compressed air and equal distribution of pressure, closed-loop systems ensure that all points in the system receive the same quality air. This allows everyone to work simultaneously without worrying about enough air reaching the end of the line. When compressed air storage is included in this system, you have even more flexibility to run multiple tools or processes simultaneously. With a main loop, you can keep the airflow centric without investing in oversized pipes. The pipe remains horizontal, and tapping flanges are installed to drop the air down to your desired location. Leaving the main section horizontal makes the installation process more manageable. Satellite Air Piping System Combining the last two layouts, antenna and closed loop, satellite air piping systems consist of one giant loop with secondary or satellite loops coming off of it. This yields the benefits of a closed-loop system for the entire facility and the point-of-use loops. Satellite systems are most often used in more extensive operations. With individual satellites and shut-off valves, you can perform maintenance on one while the others remain operational. Splitting your air into these different satellites gives you more control over the air at points of use. In large-scale operations, air treatment can be adapted to suit the individual loop. This will allow you to use better-proportioned tools in each application, saving you money on equipment that uses less air. Gridded Air Piping System The gridded air piping system is the most elaborate layout for your compressed air system. Rather than extending out to individual closed loops, the entire system is a closed loop. The loop is then “strengthened” by the secondary lines that are included in the loop. These “secondary” lines optimize the efficiency of getting air to the individual drops. Typically, the grid introduces a run of pipe into the middle of your loop. This middle section of pipe will then branch off from the center to rejoin the exterior loop. These branches create smaller loops inside the main one, ensuring identical flow at all points of the compressed air network. By implementing more pathways for the air, you can limit the overall size of your compressed air pipe. Before You Buy Before you build a compressed air piping layout, ensure that you are covering all of your bases. Check that you are using the best material for your operation, achieving the desired airflow at the desired pressure, and that your compressor can fulfill the demand. Get a Air Piping Layout Created For FREE by Warthog Air Compressor Store If you are hesitant to build your own compressed air piping layout, you’re in the right place. Warthog offers complimentary piping layouts and quotes for your compressed air system. In order to get a layout done for your compressed air piping, our technicians require some information about your operation. Facility layout Dimensions are needed for accurate quoting Total Drops Provide ideal locations if possible Pipe Diameter Pipe size gives us a reference point for your system Additional Considerations Compressor is outside, unique requests, anything that the design technician should be aware of. With the right information on your compressed air system, our design technicians can build you a layout with highlights on key installation areas. Alongside the piping layout, you will receive a quote with all the necessary components to bring the diagram to life. Use the below form to submit a request for your compressed air piping layout. If you have a preference from the layouts we discussed prior, feel free to include it on the form. Hand made drawings and notes can also be included for additional reference points.
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The Best Parts Of The Rotary Screw Compressor
Now, if you’ve been around compressors for at least a week, you will have heard of a rotary screw air compressor, you know, the one you have if you don’t have a reciprocating compressor. Both of these compressors are positive displacement compressors; the main difference between the compressors is their applications and the way the units are built. Rotary Screw Compressors do not use valves like the reciprocating compressors do to move the air downstream.These compressors have become an industry staple due to their reliability, noise level, and efficiency. Through the use of two motors, pressure is created to compress the air. The simplicity of their design makes these some of the easiest compressors to use and maintain. The standard enclosure features technology to reduce the noise of an air pump that is already much quieter than a reciprocating piston compressor. The way that the rotary screw compressor starts and stops uses less energy than the reciprocating piston would in the same environment.Now how did this machine come about? Is it a modern revelation or a cumulation of time and energy going into making a machine of that caliber? Well you may be surprised to know that the original patent for a “Screw Blower” #4121, was obtained on March 24th, 1878 by a German engineer named Heinrich Krigar. He would then go on to receive two more patents for his 2+2 helical compressor that was capable of making less than 2 psig. So this technology, although nowhere near as refined as it is now, was incredibly groundbreaking.These compressors have come a long way in 145 years from just under 2 PSIG to machines that are powerful enough to power an entire manufacturing facility. So just how far have these compressors come and how do they work now? How Does The Rotary Screw Compressor Work?The main components of these compressors are the male and female rotors. In order to create pressure, these two rotors turn in opposite directions. As the air is moved through the rotors, the space between the individual rotors, as well as the housing for them, is decreased to create compression. Each individual screw component has a built-in pressure ratio that is fixed based on the length and pitch of the screw as well as the shape of the discharge port. These fixed ratios are crucial to making sure the built in pressure ratio is properly adapted to the working pressure.Now that the more technical explanation is out of the way, let’s take a look at the step by step process of how rotary screw compressors create compressed air: Gas is sucked into the compression chamber, which consists of the two screw rotors. As they rotate, the air is isolated in the cavities and moved down the chamber through the rotors. The overall size of the chamber decreases as it moves away from the opening. This process decreases volume and increases the pressure. The pressure builds and the air is condensed. Once the pressure has reached the threshold, the discharge valve will open and move the air into the next step of the process, whether that be dryers, storage, or filtration. The process of compression is streamlined and requires less internal movement of the air in comparison to the reciprocating compressors. The air is pulled in and as it moves through the compression chamber pressure is applied to compress it. No matter the variation, this process remains the same across all rotary screw compressors. These aptly named compressors are known for their consistency and efficiency and they can come in oil lubricated or oil-free.https://youtu.be/qW2RANdPUJ8 Wait What Needs OilRotary Screw compressors are typically divided into two main technologies when it comes to their oil usage: Oil-free and Oil-injected. Both of these options cover all of the needs for rotary screw compressors. If there are high air quality standards, you might need an oil-free, but for everything else the oil-injected is going to work just fine. These two technologies are often referred to as dry and wet screws respectively.The main difference, besides oil content, is how the rotors spin: Oil-Lubricated Screws the male rotor drives the female rotor Oil-Free Screws a timing gear is responsible for ensuring a calculated clearance between the two rotors. Oil-Free Rotary Screw CompressorsThis variant of compressors comes with an asymmetric screw profile to boost energy efficiency and reduce internal leakage. These compressors rely on the timing gear to prevent any contact between the rotors. This results in high-speed compressors with unmatched efficiency that also delivers extremely clean air on demand; however, in order to reach this level of quality the attention to detail needs to be extreme.External gears are the key component for making sure that the screws are synchronized to prevent any unwanted contact between the two. By preventing contact between the rotors and the housing from occurring, there is no need for lubrication to be present on the rotors. This allows the byproduct to be completely oil-free. Without having any oil in the compression chamber, these machines are able to deliver air that is completely oil-free.These units typically work in several stages due to the built-in pressure ratios limiting the components. Through multiple stages and intercooling between them, these compressors can reach higher pressures while still not using oil to help cool the air internally. This helps to limit temperature differences between the air being brought in and the final product. Temperature is important to monitor in oil-free compressors due to the way they heat up rapidly.These compressors do not have the oil in the compression chamber to help reduce the temperature of the air back down to recommended limits. This creates a need that is not present in your standard oil-injected screw. It requires adequate lubrication on bearings and bearing surfaces to ensure reliable and efficient operation. Overall these machines come at the cost of needing more mindful maintenance, but the product these machines create is unlike any other compressed air.Oil-Injected Rotary Screw CompressorsCompletely opposite of the oil-free model, the oil injected/flooded/lubricated goes by many names for the same process. These machines use oil that has been injected into the compression chamber to lubricate the components, as the male rotor is responsible for driving the female rotor in these machines. Friction is impossible to avoid when one component is responsible for turning another and lubrication is needed to make sure that friction does not wear down the parts.With friction comes heat, and this heat needs to be removed from the air before it goes downstream and potentially causes problems with the equipment. By removing heat from the air stream, the amount of vapor present in the air stream is reduced and minimizes leak potential. Although more oil is being introduced into the compression chamber, the air and equipment benefit greatly from this being introduced.Even with the benefits of compression, it's important to ensure that as much oil has been removed from the air as possible. Compressors often have a centrifugal separator to help remove and reuse the oil. This method does not remove all of the oil, there will be some carry over downstream as the oil passes through in the air. This oil will be removed downstream by passing through filters and a dryer. The oil that's removed from the air is cooled down and recycled back into the chamber to continuously cool the air.Depending on the application, compressed air may undergo more or less filtration than others. This is ultimately determined by the air quality standards and specifications like temperature, CFM, and PSI can all create a difference in your performance. It is important to know what your individual application needs when it comes to determining the details of how your compressor operates. Rotary Compressors Can Run at Whatever Speed You Need With VSDsWhen it comes to rotary screw compressors, they have access to technology that no other compressor can compete with: The Variable Speed Drive (VSD). VSDs can go where no other compressor can, they can match the rate of production to your needs.When it comes down to it: Fixed Speed compressors run at one speed when they are running, they are either on or off Variable Speed Drives run at the speed necessary to fulfill the current demand. Why Would I Want a Fixed Speed?Fixed-Speed compressors when properly sized will deliver when they are needed. These machines run at 100% of their capacity or 0% and no in between. The problem here occurs when the machine is winding down and the motor is not producing air but is still rotating and using energy. This means precious time and money is being wasted whenever the machine is not running at full capacity. So if this machine isn’t as efficient as a VSD why would it be something you would want to invest in?The main differentiator between the two, aside from speed, is the initial cost. VSDs can be a lot more expensive upfront. Fixed Speed compressors can be a valuable asset to your operation if you need a continuous supply of air. IF you just need air consistently, the fixed-speed compressor will be the right fit for you. That being said, you will still be wasting valuable energy and money when the machine is not in use.https://youtu.be/RYMELetN5Ys Should I Use A VSD Rotary Screw Compressor?The VSD currently has a monopoly on energy efficiency. No compressor can compete with the energy savings that come with using a VSD. These compressors can save you anywhere from 35-60% of your total costs of ownership. Although the initial investment may be steeper than a fixed-speed rotary screw compressor, the Variable Speed Drive will end up paying for itself in no time.These machines are the unsung heroes of slow production days, slow second and third shifts, and understaffed periods. Changing operational speed to match need reduces the energy usage during slow periods. So in short, on slow days the VSD will save you more money than any other compressor would.Where Would I Use a Rotary Screw Compressor?With the rotary screw compressor, there are a multitude of different applications that it can be used for. From manufacturing to pharmaceuticals, these compressors can simply get the job done. They are built to handle whatever you throw at them.The Typical Applications for Rotary Screw Compressors: Food and Beverage Manufacturing Painting Automotive Agriculture Food Packaging Construction Energy HVAC Of course this list is not all inclusive of every possible application for a rotary screw compressor. This is in place to give you an idea about whether a screw is right for you. Before You BuyRather than delve into the details, let's go over the benefits to going with a rotary screw compressor. There are five main points we are going to focus on. Energy Efficiency Due to low heat emission and the potential use of a VSD, these machines are more energy efficient than their reciprocating piston counterparts. Long Lifespan A combination of easy maintenance and low heat emissions make this machine the ultimate workhorse. These machines can run full at full power 24/7 and still experience minimal capacity loss. Continuous Air Flow Plan and simple, there is no need for a cooldown period and that allows these machines to keep working and avoid overheating issues. The only time it would take a break is when there is no longer any capacity. Noise Volume With these motors not being in direct contact with each other, it creates a quieter environment around the compressor. Not only is the basic unit quieter, these machines can be made nearly silent with the right add ons. High Capacity Due to 24/7 compression, these compressors can make higher volumes of air than other models of compressors. Now all that’s left is for you to go get your own rotary screw compressor for your own application. These workhorses can be found from the best brands on our website. With access to the latest in VSD technology and compressor technology in general, you won’t be able to find a better machine. All it takes is a few clicks and you can be looking at the best fit machine for your application. Shop with us today. Learn More From Atlas Copco From The Compressed Air Blog From Mark Compressors
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Types of Air Dryers, Made Easy
Deciding Between Types of Air DryersBefore we talk about the different types of air dryers we need to talk about why you need a dryer. Having a dryer is a crucial part of producing high-quality air and making sure your system can keep operating smoothly. Dryers are responsible for removing the moisture and water vapors from your air stream. As we know, moisture is the enemy of all compressed air systems. It ruins the piping, can cause condensate build-up, and creates problems downstream. Now it may seem obvious that the best way to fix this is to install an air dryer, a machine built to remove condensate from the air stream.However, the fix is not quite that simple. Yes, you need a dryer to remove condensation, but what type of air dryer do you need? Well to answer this, you need to know what your air is being used for and the quality standards for that application. Every use of compressed air is unique in its own way. Some applications require air with an extremely low dewpoint, others just need a large majority of the moisture removed, and some need super high-quality air with no moisture whatsoever in it.To reach each one of these standards, the air needs to go through different processes. Low dewpoints can be achieved through the use of desiccant dryers, while general moisture removal can be accomplished through the use of a refrigerated dryer, and if you have a low need for compressed air, you may end up using a simple membrane dryer to remove the moisture for the health of your pneumatic tools. But what is the difference between these different types of air dryers and what makes them unique? https://youtu.be/_CB_D9Cv1g8?si=Lw3oCr9XHLgaAvj7 It Isn’t as Simple as Dry or Wet AirPicking the right type of air dryer is not as simple as we would like. We need to break down the environment that this air is being compressed in and the uses of that air. The factors you need to be aware of are: Air and environmental factors Inlet air pressure Inlet air temperature Ambient air temperature (and water temperature if condenser is water-cooled) Installation environment of the dryer Maximum air flow in standard cubic feet per minute (scfm) Desired pressure dew point Dewpoint and relative humidity These factors are important for properly sizing your dryer, and in some cases determining the type of dryer. The air and environmental factors are important keep in mind, the air can flow at a much slower rate than it is rated for at 100℉ and 100 PSI. Sometimes it can be difficult to determine these things as, feel free to visit our CFM calculator for dryers here. When it comes to dewpoint and the humidity of the environment, it goes hand in hand with air quality standards. Different Situations, Different DryersIf you are in a relatively humid environment and your industry requires high quality air, you are going to need to get a different dryer than someone who may be using their compressed air in a typically dryer, cooler environment and the air quality standards are not as severe. You also need to be aware of how seasons change the conditions in your compressor room. Do you have to worry more in the winter or in the summer? The key to finding the right dryer is balance and finding equipment that can handle the highs and lows.Each type of dryer has different applications that it excels in and others where it may fall short. And to make matters more confusing, there is no clear-cut winner overall. Instead, these individual characteristics of your application and environment need to be taken into consideration. With that in mind, there is a simple way to tell which dryer would be best suited for you, and that is the Class of Air Quality Standards in your industry. Anything Class 3 and above need a desiccant as refrigerant dryers can only go up to Class 4 Air due to the means by which the air is dried.Now let’s break down the different types of dryers and what each one is typically used for. We will discuss the basic functions of each type of dryer so you know how and when to use each type of dryer. This way you can make the best possible decision for your air system. The Types of Air DryersRefrigerant Air DryersRefrigerant dryers are an excellent choice for those who meet the following conditions: Ambient temperature is less than 40°C/104°F Prevent condensation Dew point around 3°C-4°C/37°F-39°F These dryers work very similarly to the way our air conditioning does at home. The air is passed through a heat exchanger which has been cooled off by the internal refrigeration. This process both cools the air and causes moisture to condense by reducing the temperature. This process can be constant or operate on a cycle that helps improve energy efficiency. These dryers are the most energy efficient of the bunch as they allow heat transfer to do most of the work and the machine has to focus on maintaining the refrigeration level.Refrigerant dryers pose the risk of freezing the pipes in suboptimal conditions. If the temperature of the inlet is too low, moisture can freeze as it passes through the heat exchanger. Not only can the temperature cause a problem when the ambient air is too cold, but the opposite can have negative effects on the system as well. If the ambient or room temperature air is over 104°F it can become too hot for the dryer to handle and result in excess moisture continuing downstream, as well as slowing the movement of the air in your system.Do to these restrictions, refrigerant dryers cannot reach some of the more stringent ISO Standards. These dryers have a lot of great applications and can be extremely beneficial to the health of your air system, but they cannot provide those same benefits for every application or even every location. High Temperature Refrigerant Air DryersIf your compressor is lacking an aftercooler, which you should have for the health and longevity of your system, or the compressor room has a temperature surpassing the 40°C/104°F threshold then you should invest in a High-Temperature Dryer that is built to handle those conditions. These dryers are refrigerant dryers that have been manufactured to go beyond where the traditional refrigerated dryer might fall short. Desiccant Air DryersWhen it comes to desiccant dryers, AKA adsorbent, the rule of thumb is if you need a low Pressure Dewpoint or high quality extra dry air there is no question. Desiccant dryers can drop the PDP of the air down to -40°C/-40°F or -70°C/-94°F, depending on the level of drying. The ability of these dryers to drop PDP to such a low temperature is second to none when it comes to removing moisture from the air and making sure that moisture does not condensate again during use.Now you might be wondering how exactly these dryers work. Adsorbent dryers typically consist of two different towers filled with an adsorbent called desiccant. The air is passed through one tower and as it passes over the beads, the moisture and humidity is collected. The air only passes through one tower at a time, and it allows the tower that is shut off to dry the adsorbent and help extend the lifespan of the desiccant beads.This process is often sped up through the use of purge air. Purge air is pulled from the air stream to be sent down the other tower and expelled out the bottom. Reaching such low PDPs comes at the cost of valuable air being lost to help dry the beads. It may seem detrimental, but if this was not part of the process the air quality wouldn't meet Class 1, 2, & 3 ISO Standards. Each dryer excels in different areas but at a different cost. that is why it is important to review your needs when buying new equipment. Membrane DryersUnfortunately, membrane dryers, are considered the red-headed stepchild of compressed air dryers. Using condensation to remove the water vapor from the air stream, they are on there way out of the industry. The process does not yield as efficient of results as the other methods of drying air. However, that does not make them completely useless. An affordable option and take up much less space than other options, especially to simply remove moisture.Membrane dryers need to be adequately sized to the air flow to ensure the most moisture is being collected from the air stream and removed properly. These dryers can be easily overwhelmed and fail to remove water vapor which will cause problems downstream. If you choose one of these dryers it is incredible important to size it properly. If not you will be spending more to fix your system than the initial cost would have been. Before You Buy Types of Air DryersThere is no one size fits all when it comes to air dryers, in fact its the opposite. Each application needs something specific. These specifications mean a lot of variables need to be accounted for when considering an upgrade or a replacement.If you are looking to get a new air dryer but still need help making sure you get the right equipment, you came to the right place. All of this information on properly sizing, air purity classes, means of drying the air, are all incredibly important but can be overwhelming. Feel free to reach out to one of our representatives who are knowledgeable in compressed air and want to make sure you get the right fit.If you would rather do it on your own, we totally understand, but we still want to make sure you get the right equipment. Feel free to use the resources on our site such as our Dryer Sizing Calculator or any of the information under Warthog University. Our goal is to change the way you buy compressors online and that starts with our customers. Learn More Visit Warthog University More From Atlas Copco More From Pneumatech From The Experts
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Common Uses of Compressed Air
Compressed Air has many uses and is vital to the success of a lot of industries, whether it be used in-house or a product earlier in the supply chain. Air is considered the 4th utility and that often gets overlooked by the general population. Something that is so prevalent is often disregarded both in usage and care of this utility. Most people don’t even know that Air is considered the 4th utility, let alone the applications where it is a necessity. Take a look around you and make note of what is sitting around you. Do you have a plastic bottle? Perhaps your medication is nearby or you took it this morning using that same water bottle. No matter your location or what you are doing the results of using compressed air can be found around you.Uses of compressed air can vary depending on the product and the industry that it is in. A paint and body shop needs air to help spray paint onto their cars, while another plant may be using compressed air to expand plastic, and a third may be using compressed air to simply move products through the facility. Air can be used for a wide array of applications and each application might use air in a different manner. How Do People Use Air? We briefly mentioned some of the versatile uses of compressed air, but the real question is how real people use it. In what ways is it benefitting these individuals? With the variety of uses available, it would take ages to talk about all of the potential uses of compressed air. Rather than that, let’s dive into some of the most common uses of compressed air. Home Uses of Compressed Air When it comes to home use of compressed air, everything from small hand-held machines to larger 60-gallon tank-mounted machines can be used. Whether it be for leisure or getting work done around the house, compressed air is used by many in their day-to-day lives. Some of these compressed air uses are: InflatingAlthough these air pumps may be simple looking and some even require manual effort to move the air, compressed air plays a large part whenever you need to inflate something. A list of common inflatables are: Bike/ Car Tires Balloons and Pool Accessories Air Mattress Sports Equipment Pressure Washing Now pressure washing may seem confusing as it sprays out pressurized water. The thing is something has to pressurize the water coming in from the hose/tank so that the water can be sprayed out and used to clean off other surfaces. Pressure washers are most often used for cleaning outdoor areas of properties. Removing dirt and chemicals from siding, bricks, and decks makes the pressure washer a valuable commodity.Woodworking and CarpentryWhen it comes to woodworking, compressed air benefits everyone from the most seasoned veterans to woodworking hobbyists. Pneumatic tools like nail guns run on compressed air and that air-powered equipment allows them to make more with less work. Air also works to help remove imperfections in the wood, help sand down the wood, and for continuous work on a median. PaintingWhen it comes to painting, compressed air is the key to efficiency. By using compressed air, the paint can be sprayed evenly over a wide area or if detail work needs to be done it can power an airbrush. Various Projects/ Yard WorkWhether it be in the garage, basement, or yard, you can benefit from using compressed air around the house. Air-blow guns can help with cleanup, or making a leaf pile for the kids to play in. It can also help you spread weed killer over large areas of your lawn without having to move. When it comes to your home there are many different applications for compressed air. Although it may not be a necessity like in industrial applications, compressed air can help make your life at home just a little bit simpler and make some menial tasks a little bit more exciting. It's extremely important to remember that compressed air needs to be used responsibly. If used incorrectly it can cause irreparable damage to you or someone around you. Small Business Uses of Compressed Air When it comes to small businesses, uses of compressed air are typically a power source for power equipment and tools used during the production process. These groups use commercial air compressors rather than consumer or industrial ones. So in short, these machines are bigger than the traditional handheld air compressors you might find at Home Depot, but not as big as the machines in an industrial air compressor room. Small businesses can be dependent on air compressors for their individual success. Most of these businesses use pneumatic tools and air compressors are needed to power those tools. Pneumatic tools provide them lighter and safer options in comparison to electric tools. These tools won’t overheat like electrical versions do after long use. This allows them to use the tools for longer without worrying about potential accidents happening with their tools. Some of the most common applications of commercial compressors include: Auto Body Shops Dentist Offices Construction Pneumatic Tools Cleaning Keep in mind that these are only some of the applications in which compressed air can be used and there are many other applications for commercial air compressors. Many individuals have even set up commercial-sized air compressors in their own homes. Industrial Uses of Compressed Air When it comes to industrial demands, some industries have no choice but to rely on compressed air. Unlike electricity, the only place of excess heat in air compression is at the site of compression. Released heat is often reintroduced at a different location to help improve energy efficiency. Removing heat makes the downstream use of air much safer. No risk of overheating and potentially causing a reaction between heat and explosive materials.The demand for compressed air has constantly been on the rise and due to this technology has followed suit and introduced different technologies like the rotary screw compressor and even more recently the variable speed drive that makes these machines, even more, energy efficient. This has allowed the uses of compressed air to expand as they were able to do more with the same machine,Industrial uses of compressed air are much larger and typically have more components in their air system than a mom-and-pop shop might have. These shops have what they need to get a small job done, but when the requirements are much steeper like an industrial application where it needs to power the whole facility and the individual components downstream. These industrial uses of compressed air can vary from agriculture and farming to pharmaceuticals. Some of these uses of compressed air include:ManufacturingCompressed air is the central power source for a lot of manufacturers, especially those working with plastics, metal, assembly, or refineries. These businesses are reliant on production and without compressed air, there is no production. Compressed air is responsible for: Operating Tools Air and Welding/Cutting Efficiently performing basic tasks Blowing plastic into a mold Monitoring Production Sandblasting and finishing meta Automated machinery AgricultureWhen it comes to farming, compressed air makes potentially difficult tasks easier. Providing long-term performance benefits alongside a low cost of ownership. Agriculture uses compressed air to move feed and grain, ventilate greenhouses, spray crops with pesticides and nutrients, and even be used as a power source for dairy machines. Farming benefits from the use of compressed air, so just remember the next time you have something with cheese, grains, or seeds that compressed air helped make that. PharmaceuticalsCleanliness is key when it comes to pharmaceuticals. We want our medicine to be what the label says it is and not have to worry about the quality of our medications. Highly regulated industries require equipment that is accurate and precise while performing at the highest level. These machines move products on the conveyor belts, spray the coating on pharmaceuticals, and bottle/package the products. Dry CleaningNow, this might be an unexpected and simultaneously obvious application of compressed air. Dry cleaning relies on a reliable supply of air to clean the items that come in and to operate machines like steamers and laundry presses. This industry is about quality and consistency and that is what compressed air grants them. Food and BeverageLast but not least, is the industry that affects us every day, the provider of sustenance that keeps us alive. They need clean, quality air to power their systems. These operations are consistently occurring to keep up with demand and with that, there can’t be any contamination. Compressed air is used to: Cool and freeze products Filling up drinks Closing and checking devices Packing and putting finished products on pallets. These industries and many more are extremely dependent on compressed air to be able to operate at maximum efficiency and maintain desired output. Compressed air is responsible for many different components of our daily lives, it also makes the production process much easier for those involved. The uses of compressed air are continuing to be expanded upon and critiques to make sure every application is getting the most out of compressed air. The only way you can reach these expectations is when you use the best products, just like the ones we carry at Warthog. Before You BuyWhether you have a current air system that needs to be updated or are looking to get your own, trust in the Atlas Copco Family of Brands. They are of the highest quality and are top-of-the-line. As they continue to push the boundaries on energy savings and technology to increase the efficiency of their machines. To get the best of the best for your personal and professional use, there is no better option than Warthog Air Compressor Store. Looking to Learn More?More From Us: Warthog UniversityMore From Atlas Copcohttps://www.youtube.com/watch?v=8XDmu7dov-Q More From Quincy
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Why Should I Care About Quality Compressed Air?
Compressed Air is the 4th utility, a staple in manufacturing and production. It enables you to work in areas that may have been dangerous and lets you take your power with you. The versatility of applications makes it a precious utility, especially in industries where cleanliness is vital. Having quality compressed air is a necessity that may not always be at the front of everyone's minds, and keeping tabs on it will set you and your air system up for success. Air is DirtyRegarding these systems, the output is only as good as compressed air quality. The ambient air around us contains small amounts of particulates, moisture, and even oil vapors, which don’t even include the oil from the compressor itself. Once this air has been compressed, the widespread molecules of those particulates and moisture become concentrated and condense together. Increased concentrations can cause moisture buildup in the pipes, making your air completely unusable in applications like food.Contaminated air can cause a problem in every compressed air application as it can deteriorate the system from the inside, increase the necessity of maintenance, and shorten the lifespan of your equipment. Still, it can be the difference between production and being completely shut down in applications requiring clean air. Industries based around human consumption, food, breathing air, and pharmaceuticals are just a few industries highly dependent on clean air. Oil, dirt, or water getting into products would be detrimental to the users' health and the company's reputation. Dirty Air is Wasted AirWith wasted production comes wasted money. This can be the difference between your company feeling financially comfortable or stretched too thin. When machines are poorly maintained or simply inefficient, they can be responsible for large amounts of wasted money on utility bills. Unclean compressed air is the culprit behind unnecessary financial problems and problems in your system, but it can also reduce the lifespan of pneumatic tools and increase the maintenance required. The air around us is full of particles that, in small amounts, don’t cause any problems. However, when that air has condensed, the concentration of the particles increases and can cause problems. How do you get rid of those molecules, moisture, and muck in your air system? Prevent those particulates from getting stuck in your pipes, machinery, and equipment, making your life harder. Getting rid of those particulates comes down to getting the right equipment, but you need to know the air quality you need before choosing the right equipment. What is Quality Compressed Air?Choosing the quality of your air depends on a straightforward thing and that is how you are using your air. How you use your air determines how clean it needs to be, plain and simple. Most industries have requirements that align with ISO Purification Standards. Providing a guideline on how to properly clean your air and what the maximum concentrations of particulates are acceptable for each class. ISO standards ensure your system produces Quality Compressed Air for your compressed air application. These standards will give you a goal to aim for with your air quality, along with the necessary information to make the right decision in purchasing your equipment.Now that you have an idea of what you are looking for to produce high-Quality Compressed Air, it might be helpful to understand what it is. High-Quality Compressed Air is ambient air that has been compressed down in a compressor and then passed through a series of condensate treatments, moisture removal, and filtration to remove particulates from the air. Quality Compressed Air Qualifications Oil Content Dust Content Water Content Dewpoint Microorganisms & Contaminates For air to be considered Quality Compressed Air, it needs to have trace amounts of particulates, contaminates, and water while having a low enough dewpoint that condensation will not form when exposed to the ambient air. Quality is determined by parts in the air; the more pure the air is, the closer to Class 1 Air. Following these guidelines will ensure that you a clean system, smooth production, and quality compressed air. With a basic understanding of the benefits of removing particulates, oil, and water from your compressed air stream, you may now be wondering how you ensure that you are following the ISO Standards to produce clean compressed air. The solution to creating quality compressed air is the proper equipment in the right spots downstream. How to Make Quality Compressed AirMoisture and particulates have no business in an air stream, including yours. They provide no benefit to air production or movement and do not belong at the point of use. Removing these contaminants involves two significant pieces of equipment in every air system: a dryer and filters. These pieces prevent damage to your system and extend the life of your equipment while avoiding wasted energy. DryersThe mortal enemy of moisture in your air system is a dryer. These dryers can come in many different models with different means of drying air. Dryers typically come in one of three styles, refrigerated, desiccant, and membrane. Most traditional applications are going to use either a desiccant or refrigerated. The type of dryer depends on the application, as both refrigerated and desiccant excel in different applications. When choosing between the two, the deciding factor typically is the air's dewpoint. Refrigerated, or condensing dryers, are commonly used when Class 4 air is the maximum air quality required. For lower dewpoints, a desiccant dryer would be the necessary equipment to properly dry your air. Desiccant Air dryers excel for applications requiring Class 3 air and up.Drying your air is the most critical step to removing moisture from your air. It can help remove vapors and moisture molecules. Reducing the air's dewpoint requires a lower temperature for the moisture molecules still in the air to turn into condensate. Lowering the temperature to -70℃ makes it nearly impossible for the moisture to condense when it is exposed to ambient air or is at the point of use. This is beneficial to the end user, not having to worry about moisture and for the overall health of your system. FiltrationWhile dryers are responsible for removing moisture from the air, dryers do not remove oil, dirt, and other particulates from the air. A solid filtration system is needed to remove particulates and oil from your air stream. Now it may sound like a simple solution; throw some filters on your system downstream, and all the particulates will be cleaned out. If only filtration worked in such a simple manner.When it comes to filtering your compressed air, you must pay attention to the little things. Filters are classified by the filterable material and the size of the holes in the filter. Filters that can stop dirt and particulates are called particulate filters, while coalescing refers to filters that take oil out of the compressed air as it passes through. Both types of filters can come in an array of Micron sizes from upwards of 70µ down to .01µ. Problems can arise during filtration based on the sizing of the filters. If a smaller filter is in front of a larger filter, the large molecules will clog up the filter and cause a pressure drop. A large enough pressure drop can ruin the filter. The finer the size of the filter, the later downstream it needs to be. Like the idea of nesting dolls, you have to go through the bigger ones to reach the smallest layer. The lifespan of your filters needs to have proper filtration before the filters with finer filtration.Filter SizingStart with your largest-sized filter, which is typically a particulate, to remove the big particles of dirt and dust flowing through the air stream. Following your particulate filter, you would want to use a finer filtration than the previous one but not so small that it would end up getting clogged. It is imperative to know the size of your filtrations so that you do not clog up your filters and cause problems downstream.When it comes to filters, there are just as many variations and options as there are compressors; therefore, it is essential to be aware of your system’s needs when adding equipment to it or changing out pieces that were in use. Knowing the individual details is vital to making changes to your air system and adequately servicing them. If you don’t do this, you won’t be able to produce high-quality air. https://youtu.be/7vot8o8O2n8 Curious to Learn More? Check out Warthog University Looking for your own Filter? More from Atlas Copco More from Chicago Pneumatic
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Why Should I Check My Actual CFM?
In short, you need to calculate your Actual CFM output for your dryers in order to ensure the success and longevity of your equipment.When it comes to your compressed air system, knowing the requirements for your system is vital for your operation and for upgrading your air system. Adding new pieces downstream can be vital to maintain productivity and keeping your system running smoothly for as long as possible. These pieces need to be able to be added seamlessly to guarantee the success of your system.Now you might be thinking that it is pretty obvious how you check the actual cfm, it is simply the output of the compressor, however that machine compresses the air will determine the CFM output. Going off of this idea is not inherently wrong as the compressor output is an accurate representation of how the machine is operating, however, when it gets further downstream, more factors can come into play in determining the actual output of your air system.Dryers can be difficult to properly size as they need to reach specific CFM requirements but also ensure the air is coming out dry and of good quality. Factors such as air temperature and system pressure can drastically change the output of your air system, and when the factors align it can reduce your CFM by up to 50%. This massive reduction can increase the stress on your dryer and greatly reduce its lifespan due to how much harder the machine will have to work to keep up with demand.Even though a majority of pressure and temperature combinations can be responsible for reducing your CFM, some can even increase the flow rate of your air as well. This variability makes it extremely important to be able to find the right fit for your dryer. If you undersize your machine it can fall short and nearly eliminate its lifespan. Finding the right combination is simple and easy with the Warthog Calculator. Using standard multipliers, the calculator is able to determine the efficacy of dryers to be able to determine the actual output.This calculator will help you determine the exact Air Flow that your machine and system will be putting out. All it takes is the basic information of your air system such as the temperature of the compressed air, the pressure on your compressed air, and the CFM output of your compressor. This calculator will then give you the actual CFM of your dryer under those circumstances and help you to be able to size up or downsize your dryer in order to reach your compressed air requirements.Take me back to the dryers
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