10 Common Compressed Air Myths: Busted!

Myth #1: Bigger is always better!

It seems like this statement would be true- a bigger compressor, is better for your operations no matter what, right? This couldn’t be any more wrong! An oversized compressor can actually hurt your operational efficiency and increase your costs unnecessarily. Energy usage makes up about 80% of the cost to operate your air compressor and the larger the compressor, the more energy it uses! So, if you are operating with a larger compressor than your demand requires, then you are also consuming more energy than necessary and increasing your energy costs, which can add up to thousands of wasted dollars a year! The best compressor for your operations is one that is properly sized to meet your demand to optimize efficiencies and costs. That’s right, this means a smaller compressor could be a better solution for you- thus busting the myth that bigger is always better. 

Myth #2: All compressed air oils and synthetics are created equal.

Not all oil and synthetic lubricants are created equal. In fact, the type of lubrication used in your machine can greatly impact its performance! Oil is generally defined by its viscosity, or grade, to categorize the type of oil it is. Each specific air compressor comes with its own manual that recommends the type and grade of oil you should be using. Determining, which is right for you, depends on your intended compressor usage, duration of operation, and frequency of operation. To learn more about air compressor oil and lubrication, read our blog post: AIR COMPRESSOR OIL 101: ALL THE BASICS YOU SHOULD KNOW.

Myth #3: Variable Speed Drive (VSD) compressors are always the most efficient option.

It is true that VSD compressors offer many efficiencies for some operations, BUT, this is not true for all operations relying on compressed air. Variable speed drive compressors are designed to operate between a range of speeds to accurately match the demand. These compressors are especially helpful for operations where demand fluctuates often, demand may vary by shift or season, there are strict tolerances for operating pressure, and/or your compressor will be located in a temperature-controlled environment. These machines also carry a higher initial investment that may not be feasible for some businesses. So, if your business operates at a consistent demand level with little fluctuation, demand does not vary much by shift or season, there are not strict pressure tolerances, and/or you do not have a temperature-controlled environment for your compressor- a VSD machine may not actually be the best, most efficient option for your facility! You can learn more about variable speed drive compressors by reading our blog post: GOING GREEN WITH VARIABLE SPEED DRIVE CONTROLS. 

Myth #4: Compressed air is a cheap source of power and energy. 

While compressed air is not always the most expensive power and energy source, it is also not cheap. It takes a high amount of electricity to create compressed air. About 80% of your compressed air system’s lifetime costs come from its energy, or electricity, usage. Compressed air can become even more costly if leaks go undetected or unrepaired, as this contributes to wasted energy that you are still paying for. Maximizing efficiencies in your compressed air system is the best way to control costs associated with operating an air compressor. 

Myth #5: Compressed air is extremely safe to use.

Unfortunately, compressed air is only safe to use after proper training and precautions have been taken. Air compressors push out air at very high pressures, velocities, and temperatures that can cause harm if it encounters a human in any way. If this compressed air is directed to the wrong places, not only can it cause dangerous harm to humans, but it could damage the environment, workspace, and products as well. Training is crucial for those who will be operating air compressors or working around them. When all safety precautions and guidelines are followed, air compressors become safer to utilize. 

Myth #6: Where you place your air compressor in your plant, does not matter.

Your air compressor is probably one of the most important pieces of equipment in your factory, as it powers many of your operations needed to conduct business! Because of this, it is important that your air compressor is in a clean, well-ventilated area with ample space around the machine for maintenance, ventilation, and heat regulation purposes. Dirtier environments will impact the quality of the impact air, causing your compressor to have to work harder to clean this air, or potentially become backed up by debris that enters the system. The closer the compressor is to the point of use, the better, as the risk of pressure drop increases with further distances and larger amounts of piping. The location of your compressor can heavily impact the efficiency of your operations, the quality of air the compressor pulls in, and the ease of maintenance on your machine. 

Myth #7: A few small air leaks will not impact your system’s efficiency.

Small air leaks can mean major efficiency losses and massive cost increases! Leaks can waste as much as 20%-30% of your compressor’s output, which is output that you are still paying for in energy costs. Even small leaks that go undetected can heavily impact your operations, making it essential to perform leak detections to locate and repair these leaks. Zorn Compressor & Equipment has a team of experts that can perform comprehensive leak detections and repairs for your system that may even provide energy incentives with our local energy partners!  

Myth #8: Pressure is the most important and only factor to consider when selecting the right air compressor for your operations.

While pressure is an important metric to consider when choosing an air compressor, pressure must be considered in tandem with flow to accurately size a compressor to your operations. Pressure is the force that is applied and determines the compressor’s ability to perform a specified amount of work at any given point in time. In contrast, flow is your compressor’s ability to continuously perform the designated task or application. The amount of flow required is based on the length of time needed to complete the designated task or application. 

Myth #9: The piping type and design for you compressed air system does not matter, as long as it delivers air from point A to B.

Piping material and design is a major contributor to the efficiency of your compressed air system and not all piping designs are created equally. Safe compressed air piping comes in a variety of materials, including black iron, galvanized steel, stainless steel, copper, and aluminum. All these materials boast their own advantages in different operations and environments. It is important to note that plastic piping, live PVC, CPVC, ABS, PE, and HDPE, should never be used for compressed air as plastic materials will never match the strength and durability that metal piping can provide to high air pressure operations.  
Furthermore, the design of your piping will also contribute to your system’s efficiency. The shortest piping distance, with the least number of elbows and bends in the piping will contribute to higher efficiency. The more bends and connections in your piping, the higher the risk of pressure losses becomes. The size of your pipe should also be determined by the volume and velocity of the air required for your specific applications. 
You can learn more about compressed air piping materials and design layout recommendations by reading our blog post: COMPRESSED AIR PIPING. 

Myth #10: You don’t need to plan your maintenance schedule out in advance. 

Planning out a preventative maintenance schedule for your compressed air system is crucial to its success! Zorn Compressor & Equipment is happy to schedule out preventative maintenance and service for your company, and we even provide no-hassle maintenance agreements to ensure your compressor continues operating smoothly and maximizes its lifespan!  Without preventative maintenance schedules, your compressor may be put in emergency repair situations that cause downtime and lost production in your business. Minor issues that could be fixed during routine service may never be caught if these services are not scheduled and performed, causing costly repairs or even replacements. Having a preventative maintenance schedule is the top way to ensure your compressed air system is set up for success in both the short and long run! 

Visit Zorn Compressor & Equipment’s Maintenance & Repair page to learn more about our full list of services we offer to set your facility up for success. 

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction. 

Our comprehensive product and service solutions keep you running 24/7.

• Reliable equipment
• Trusted brands
• Seamless, easy installation
• Post-sales support
• Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

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