Champion Intelli-PAK Oil/Water Separator - 250 to 1500 CFM Compressed Air Condensate Treatment

The Champion Intelli-PAK is a cabinet-style oil/water separator that strips compressor lubricant out of compressed air condensate so the water leaving your plant can legally go to a sanitary drain. Five models cover 250 through 1500 CFM, and every one of them is guaranteed, when properly sized and installed, to reduce contaminants in your condensate to less than 10 ppm for the life of the cartridge. There are no pumps, no sensors, no pre-separation filters and no electricity. Pressurized drain lines plumb straight into the cabinet.

Select your capacity from the dropdown above.

Why You Cannot Send Compressor Condensate Down the Drain

Every compressor, aftercooler, receiver, filter and refrigerated dryer in a plant makes condensate, and that condensate carries lubricant out of the compression chamber with it. Champion puts real numbers on the exposure: a single 100 HP air compressor can carry over 15 gallons of lubricant per year, one gallon of lubricant can contaminate four acres of groundwater, and raw compressor condensate typically runs 500 to 5,000 ppm of contaminants against a municipal sewer limit that can be as low as 10 ppm. Sending that to the drain is illegal in most jurisdictions, and the fines, cleanup costs and bad publicity dwarf the price of a separator. Hauling condensate away as regulated waste is the alternative, and it costs hundreds of dollars a drum.

Model Selection Chart

Sizing is based on the CFM flow of your compressed air system. Choose the Intelli-PAK that correlates with your compressor capacity. Capacity, oil handling and weight figures are as published in the Champion Intelli-PAK Series brochure. Call our compressed air engineers if you are between sizes or running more than one compressor into a single treatment point.

The Science Behind the Media

The alumina silicate substrate media inside an Intelli-PAK cartridge is formulated to attract hydrocarbons and repel water molecules. As the condensate and lubricant mixture passes through the media bed, the lubricant is chemically bonded to the media rather than simply held in it. That bonding is what makes disposal straightforward: the spent cartridge cannot leach its captured oil back into groundwater later. The media handles diester, PAO, glycol, hydraulic, food grade and mineral based lubricants, and unlike a gravity separator it will also handle silicone.

Shared Technical Specifications

A Beautifully Simple Design

• No pumps, sensors or pre-separation filters. The media bed does the whole job, so there is nothing to calibrate, nothing to power and nothing extra to service.
• Six 1/4" condensate inlets with an internal diffusing system. Pressurized drain lines from the compressor, receiver, dryer and filters plumb directly into the cabinet, which means no field-fabricated manifold.
• Smart-technology cartridge connections. Disconnect the cartridge and the internal valves close, so the change is quick and mess free.
• Proprietary cartridge encryption for aftermarket security, unlike anything else in its class.
• Rugged internal piping that holds its alignment over the life of the unit.
• Cabinet styling that looks like it belongs beside your compressor instead of behind it.

Ideal Applications

Machine shops and fabrication plants, automotive and truck service facilities, food and beverage plants operating under a municipal pretreatment permit, plastics processors, woodworking shops, printing plants, laboratories and hospital air systems, and any facility that has been cited for oily discharge or is preparing for a wastewater inspection. The Intelli-PAK is a particularly good fit where the lubricant is not fully demulsible, since adsorption media is far less fussy about fluid chemistry than a gravity separator. Pair one with zero air loss demand drains at each drop so that every drop of condensate in the plant routes to a single treatment point.

Maintenance, Disposal and the Recycling Program

The cabinet opens to a single cartridge. When the cartridge is full, disconnect it, cap it with the plugs and caps that shipped with the unit and fit a replacement cartridge. Spent cartridges can go out through your local waste management service, or through Champion's recycling program: registered units use the RMA request form at recycleoilsep.com and the recycling process itself is sponsored by the manufacturer, so your only cost is freight back to the recycle center. The supplied plugs and caps are what allow the spent cartridge to ship as non-hazardous waste.

Performance Guarantee

Champion guarantees that a properly sized and installed Intelli-PAK will reduce the contaminants in your compressor condensate to less than 10 ppm for the life of the unit. If a unit fails while operating in approved conditions, Champion will replace the failed cartridge or provide a refund through your authorized Champion distributor.

Why Buy from Air Compressor Store

Air Compressor Store is an authorized Champion Pneumatic distributor. Every Intelli-PAK ships with the full factory warranty, our certified compressed air engineers will size the unit against your actual air demand and drain layout, and we stock the matching cartridges and cabinet hardware so a media change never leaves you out of compliance while you wait on a part.

Frequently Asked Questions

How do I pick between the five models?

Size on the CFM flow of your compressed air system, not on horsepower. Add up the capacity of every compressor whose condensate reaches the unit and pick the Intelli-PAK at or above that number. Oversizing simply extends cartridge life; undersizing shortens it and can push you over the discharge limit.

How long does a cartridge last?

The Intelli-PAK is designed for six months of continuous use when it is correctly sized. Heavy carryover, an undersized unit or an unusually wet climate will shorten that, and a lightly loaded unit will run longer.

Does it need electricity or compressed air?

No. There are no pumps, no sensors and no solenoids. The unit runs on the pressure already in your drain lines.

Will it handle my lubricant?

The alumina silicate media is designed to handle all common compressor fluids including diester, PAO, glycol, hydraulic, food grade and mineral based lubricants, and it will also handle silicone. That is a real advantage over gravity separators, which require a fully demulsible fluid.

What is the difference between the Intelli-PAK and the CSP EnviroChamp 2?

The CSP EnviroChamp 2 is a gravity plus activated carbon separator that needs a fully demulsible lubricant and is serviced by replacing individual filter stages. The Intelli-PAK is a single adsorption cartridge in a cabinet, handles any lubricant including silicone, and is serviced by swapping one part number. Call us if you want help choosing between them.

How do I dispose of a spent cartridge?

Cap it with the supplied plugs and caps and send it through your waste management service, or register the unit and use the recycling program at recycleoilsep.com, where the recycle fee is sponsored by the manufacturer and you pay only the freight.