Why choose a refrigerated air dryer?

Compared to desiccant dryers, refrigerated air dryers generally offer:

• Lower capital investment
• Lower operating costs
• Lower maintenance costs
• Higher pressure dew point (more moisture left in the air vs. desiccant, but still dry enough for most shop and plant air)

Use a refrigerated air dryer when you need reliable, clean, dry air for day-to-day tools and equipment without chasing ultra-low dew points.

How a refrigerated air dryer works (simple overview)

1. Warm compressed air enters the dryer

• Comes straight from the compressor carrying moisture vapor.

2. Air passes through a refrigeration circuit

• A refrigerant system cools the compressed air down to roughly 38°F.

3. Moisture condenses out

• As the air cools, water vapor turns into liquid condensate.

4. Condensate is removed

• Condensate falls out of the airstream and is collected.
• A drain at the bottom of the unit removes this liquid from the system.

5. Dry air leaves the dryer

• Cooled and drained air exits at a dew point around 38°F.
• As long as your facility stays above 40°F, that air will stay dry in your piping and at the point of use.

Key characteristics to pay attention to

When selecting a refrigerated air dryer, match it carefully to your system:

1. Maximum pressure

• Dryer maximum pressure must equal or exceed your compressor’s maximum pressure.
• Underrated pressure capacity can create safety and performance problems.

2. Inlet temperature

• Every dryer has a maximum inlet temperature rating.
• Exceeding that rating will:
  
  Damage internal components
  Shorten dryer life
  Reduce drying performance
  
  
• A compressor aftercooler helps bring discharge air down to a safe, reasonable temperature before it enters the dryer.

3. Maximum flow (CFM capacity)

• Indicates the maximum air volume the dryer can handle.
• If the dryer is undersized, you may experience:
  
  Significant pressure drop
  Starved tools and equipment
  Reduced efficiency and reliability of the dryer itself
  
  

4. Maximum room (ambient) temperature

• Refrigerated dryers must operate within a specific ambient temperature range.
• If the room is too hot, you risk:
  
  Overheating the refrigeration system
  Nuisance shutdowns or outright failures
  
  
• As a guideline:
  
  Keep ambient air at least 20°F below the dryer’s maximum rated inlet temperature.
  
  

Best use cases for refrigerated air dryers

Refrigerated air dryers are the right choice when:

• Ambient temperature is below 50°C / 122°F
• Your main goal is to:
  
  Prevent condensation in piping, tools, valves, and actuators
  
  
• The required pressure dew point is around:
  
  3°C–4°C (37°F–39°F)
  
  
• You need:
  
  Reliable everyday plant air
  Dry air for general manufacturing, automotive, fabrication, or shop use
  A balance between cost, simplicity, and performance
  
  

Types of refrigerated air dryers

All three main types of refrigerated air dryers reach similar dew points, but they handle internal temperature and energy usage differently.

1. Non-cycling refrigerated air dryers

• Simplest design and typically the lowest upfront cost
• The refrigeration system:
  
  Runs continuously whenever the compressor is running
  If the compressor is on, the dryer is on
  
  
• Possible downsides:
  
  Freezing risk in the heat exchanger during long low-load operation
  Increased wear and energy consumption over time
  
  
• Best for:
  
  Small shops and light-duty operations
  Intermittent air use where:
  
  You only need clean, dry air occasionally
  Overall demand is not extremely high
  
  
  
  

2. Cycling refrigerated air dryers

• One step up from non-cycling units in:
  
  Control sophistication
  Purchase cost
  
  
• Key features:
  
  Refrigeration cycles on and off based on demand
  Reduces energy usage during light load or idle periods
  Helps prevent frost buildup when the unit must run for long periods
  
  
• Ideal applications:
  
  Medium-duty industrial and commercial systems
  Operations that:
  
  Run for long hours
  Have steady but not extreme air demand
  
  
  
  
• Main benefit:
  
  Better energy efficiency than non-cycling, with stable performance across typical shop conditions
  
  

3. Variable speed drive (VSD) refrigerated air dryers

• Highest-efficiency option in refrigerated dryer technology
• Use a variable speed scroll compressor with:
  
  One fixed element
  One orbiting element
  
  
• How they work:
  
  Adjust refrigeration capacity to match real-time air demand
  Maintain stable dew point even as:
  
  Flow changes through the day
  Temperatures fluctuate in the compressor room
  
  
  
  
• Advantages:
  
  Minimal energy waste at low or partial loads
  Excellent for systems that rarely run at a constant flow
  Can significantly reduce operating costs over the life of the equipment
  
  
• Best suited for:
  
  Plants with variable shifts, changing production, or seasonal swings
  Users who prioritize:
  
  Energy savings
  Tight dew point control
  Low total cost of ownership