Compressed air systems are intricate collections of parts and components working together to produce compressed air. Each machine or piece of equipment comprises hundreds of parts and pieces. Whether it is your motor, filter, dryer, or compressor, a single part can fail and render your equipment useless.
When failures occur, you have two choices for how to proceed: repair the part that failed or replace the whole unit. The decision typically comes down to cost, the cost of the part vs the cost of a brand-new unit. At first glance, it seems like a no-brainer. The cost of the part will always be less than a brand-new unit, but the costs over time can be drastically different.
When you are deciding between part replacements or brand new compressor, consider the total costs rather than the upfront costs. It may seem cheaper just to replace a valve that’s failed instead of the whole compressor, and from just the price tag alone, it is. If your valve failed as a result of a different component, your replacement will be a temporary fix to the problem.
It is hard to know exactly what is wrong with your compressor when it fails. The component that failed might not even be the source of the problem. Without being able to diagnose the problem, a full equipment replacement could be a safer option for the future.
When you are figuring out your next steps, costs are at the forefront of your considerations. These costs can come in a variety of different forms. Repairs, replacements, and inefficient output can all be reasons to look for a new compressor, but compressors are costly upfront. Leaving you with the decision to repair or replace your equipment.
As we mentioned before, costs are usually the most crucial variable when making a decision. Costs entail a lot more than just the price required to obtain the equipment. Operational costs are a whole different matter. In order to run your compressed air system, you need power, and those costs can be up to 90% of your total operating costs (Figure 1). Operating costs are your real opportunity for cost savings and can be the deciding factor between choosing to repair or replace.
Figure 1: Compressed Air Operating Costs
Immediate cost vs the long-term costs of operating your compressed air systems are vastly different. The sunk operating costs are often forgotten when considering a new unit. When you fail to consider this option, your system could be using more power to produce the same amount of air as a brand-new unit.
Depending on what part fails, the replacement process can be an easy swap. If just one component fails and it is in a serviceable location, the repair option is the clear choice. With just a little downtime and rapid maintenance, there are opportunities for an easy replacement. However, this isn’t always the case.
There can be a few different reasons for your compressor slowing down or even worse, not making any compressed air. A few possible reasons for this:
These are just a few potential problems your compressed air system may experience. Any individual component is liable to fail, not just the important ones. Issues are going to arise in your compressed air system, it is not a question of if they will.
Additional reasons your equipment may fail:
Even with a regular maintenance plan in place, failures can derail your system. These failures can be caused by a plethora of factors, and often a combination of them. Your less significant issues can be fixed through part replacements. Just find the SKU or identifier number of the part so that you can locate an exact replacement. Each instance of failure requires a different solution and should be taken on a case-by-case basis.
When you are trying to decide if you need to get replacement parts, take a look at the current state of your system. Depending on how new your equipment is, repairing old parts might not be the best solution for your system.
Your compressor’s age is a key factor to deciding whether you should repair your compressor or replace the whole unit. If it has not been superseded by a new ground-breaking technology or is relatively new, then keep looking for a replacement part. Repairs are likely the way to go if you can’t get any other benefits out of upgrading your compressor.
Repairing an existing air compressor will almost always be cheaper upfront than buying a brand-new compressor. Some telltale signs that your compressor needs repairs:
Your air compressor model can influence your decision between repairs and upgrades. With a rotary screw compressor that has been around for 10-20 years, repairs are going to be a lot easier. Your operation most likely grew over that timespan, and introducing a brand new screw compressor can be more work than just repairing the malfunctioning part(s). A new screw could require a wall to be removed entirely to fit the newer machine in. The worst-case scenario would require getting a crane or helicopter to remove the old unit and bring in the new one.
Consider repairs your first choice if your compressor is still covered by the factory warranty, has minimal hours logged, or can be repaired quickly and easily. Even if your compressor isn’t new, if it has operated routinely and reliably and the repair isn’t a symptom of a more significant issue, repairs will be the best and cheapest solution.
If repairs don’t fix your compressor’s current issues, it might be time to consider replacing the unit entirely. Unwanted downtime can cost you a lot in lost production and time. When this occurs, you are left with the choice of repair or replacement. Repairing your equipment can seem like the most cost-effective option, but that isn’t always the case long-term.
Repairs can be a great option, but they aren’t always great for long-term solutions. Replacing your equipment should be an option you consider if:
Unwanted downtime might be the wake-up call to upgrade your existing air compressor. It might not seem like it, but upgrading your compressor can save you money in the long run. Review the total cost diagram we referenced earlier; your compressor makes up around 10% of the total costs, including maintenance. The biggest thing to remember is how much you spend on energy because a new compressor will reduce that number, and keep it lower.
As technology increases, air compressors’ energy efficiency increases as well. If your compressor is older, an upgrade will improve the efficiency and reliability of your system. Although it may be more upfront, the savings from improved energy efficiency alone will make up the cost difference in no time. Not to mention that unwanted downtime is even less likely to occur with a new compressor, and if it goes down it will be covered by warranty.
There are pros and cons to replacing, just as there are for repairing. There is no one-size-fits-all solution, especially in compressed air. Depending on the state of your system, both options have pros and cons. Consider the following when it comes to making a decision:
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It is important to consider all of your options, your initial reaction might not always be the best choice. Knowing the state of your system will help you make the most informed decision.
Your compressor’s age may be the most crucial variable when deciding if repair is a worthwhile option. Repairs will be a safe bet if the compressor has recently come out of warranty but is still relatively new. If your compressor is closer to the other end of the age spectrum, it might be your sign to consider getting a replacement.
High-quality air compressors that are well taken care of can last for a long time. Depending on the model and the run time, compressors can last up to 20 years. For something like an oil-flooded screw compressor, the air end can last around 35,000 to 40,000 hours before they need a replacement, while other air ends can run up to 100,000 hours before needing to be rebuilt.
Rebuilding just the air end of a rotary screw compressor could give you a “second life” with your compressor as long as everything else is operational. Options like this are why it is crucial to consider the age of your compressor when deciding on repairs or replacement.
The age and usage history of your compressor go hand in hand, but they aren’t always a direct correlation. Compressors that are only five years younger may have thousands more hours of runtime, especially if you are comparing a piston compressor to a screw. Machines that have been reliable overall and still have some time left in their lifespan are good ones to look into repairing. However, if your system has had frequent downtime with a variety of causes, it might be time to look into replacing it.
Even brand-new compressors can be a dud, so the warranty is in place. The compressors could also have been sized incorrectly, leaving them working beyond their capabilities or too far below. If your compressor is incorrectly sized, getting a replacement could solve the problem and prevent future downtime.
Downtime is a recipe for making everyone impatient. If your compressor has experienced failures or unwanted downtime in the past, it might be a sign to look into getting a new compressor. If a compressor has failed in the past, it will likely fail again in the future. With enough unwanted downtime, you will lose more money than buying a replacement compressor.
In order to operate a compressed air system you need a lot of power. Electricity costs can be anywhere from 75% to 90% of the lifetime costs. Older equipment will push that line closer to 90%. With a majority of costs being made up by energy usage, investing in energy-efficient equipment is a no-brainer.
When you are planning to invest in new equipment, comparing the total lifetime costs of new compressors can help make the choice easier. Energy-efficient upgrades will pay for themselves within a few years from reduced energy bills alone. Compressors aren’t the only area where energy efficiency will benefit your system; the results are the most notable.
Ensure you run the analysis on your system to see what path is best for you. Whether you need repairs or a full replacement depends on its current state. Compare the differences between the costs of repairing or replacing your equipment and how that path will affect your energy efficiency.
The main thing to remember is that no one solution works for every one. Depending on the compressor model, how often it runs, the industry you work in, and many other factors play into the decision-making process. The best choice isn’t always the first choice you encounter. You’ll need to do a little math to maximize your system.
Whether you need parts for repair or a brand-new compressor, Warthog has the equipment for you. Shop our air compressors here, and if you can’t find the parts you need for repair, we have a parts request form.
No matter your decision, Warthog is here to help you improve your compressed air system.
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