Air Compressor Usage in Modern Manufacturing

Applications

Powering Pneumatic Tools

Air compressors provide the air that powers a wide range of pneumatic tools that are commonly found in manufacturing facilities, such as screwdrivers, nail guns, impact wrenches, grinders, paint sprayers, and more. 

Material Handling, Conveying, & Assembly Line Operations

Air compressors are crucial to keeping assembly lines moving. From powering the conveyor belts to powering the robots and machinery necessary to assemble products, reliable compressed air is crucial to carrying out efficient assembly lines in all manufacturing realms. 

Heating & Cooling Processes

Compressed air can power both heating and cooling processes needed for solidifying, cutting, morphing, or other manufacturing tasks. Air compressors generate a lot of heat as it is, and they can power machinery that heats materials for melting purposes. Similarly, air compressors can also provide the power to cooling devices like industrial grade fans, freezers, and other equipment.

Painting & Coating

Compressed air is commonly used in paint sprayers to push the paint out of the sprayers/guns in an even, uncontaminated, uniform layer to properly coat the designated items from small toys to large automobiles.

Blasting, Surface Preparation, & Finishing

The highly pressurized stream of compressed air that comes out of an air compressor is commonly used for blasting off surfaces or clearing debris, as well as product blow off before packaging. Depending on what the air is encountering, there are oil-free air compressor options for enhanced clean air standards required in medical, food, and beverage manufacturing applications.

Automating Control Systems & Actuators

Air compressors carry out the very important role of powering the automation of certain controls, actuators, cylinder, and valves in manufacturing facilities. Without compressed air, it is likely that many of these controls and parts would have to be operated manually.

Cleaning

Like many industries that utilize compressed air, manufacturing companies also use compressed air for general cleaning and maintenance. The high-pressure air supply from air compressors can power cleaning tools and maintenance equipment to effectively and efficiently maintain manufacturing facilities.

Choosing the Right Compressor

CFM Requirements

CFM stands for cubic feet per minute, meaning how much airflow is needed to meet demand. As a general rule of thumb, the air compressor you choose should have enough CFM capacity to meet peak demand periods, while also maintaining efficiency during lower periods of usage. 

Pressure Requirements

Pressure goes hand-in-hand with CFM requirements. It is measured in PSI, pounds per square inch, meaning it is the force or power exerted by the compressed air. The lower the pressure requirements, the more you may save on energy and cost; thus, it is important not to choose a machine with too much pressure for your required applications.

Pressure requirements will also help dictate whether you need a single-stage or two-stage compressor. Twp-stage air compressors draw air in a second time after it has already been pushed out and cooled during the first compression process. Alternately, single-stage machines only perform that first compression process. Two-stage compressors provide more efficiencies for operations that require up to 200 PSI. Any operations that require PSI below 150 are more suitable for single-stage machines. 

Air Purity Requirements

Manufacturing industries like medical, pharmaceutical, food, and beverage require higher air quality standards as the consumer will be physically consuming these products, thus they need to be free of contaminants. If your manufacturing process calls for strict air purity standards, you will want to look at oil-free air compressor options and added equipment such as air dryers and air filters.

Energy Efficiency

Some of the newer air compressors are created much more energy efficient than others. However, many of these machines may carry a higher initial investment. Is energy efficiency important to you? Are you concerned about the costs associated with energy usage when operating your compressed air system? If you answered yes to both questions, then it is important to consider energy efficient options such as variable speed drive air compressors, cycling refrigerated air dryers, and zero loss air drains. Please note that these pieces of equipment are only energy-efficient when properly sized to the right applications and may not be the most energy-efficient option for every customer.

Cost of Ownership

There is a plethora of air compressor options and technologies, each carrying a different cost associated with them. It is crucial to consider both the initial investment and the lifetime cost (energy usage, service, lubrication refills, etc.) of each machine before selecting the right compressor for your budget. 

Control Method

There are a handful of control methods available for different air compressors to properly accommodate different plant demands. You can learn more about each control method by reading our blog post: COMPRESSOR CONTROLS EXPLAINED. After you understand each control method, you can assess which is most suited for your operations to guide your choice in compressor.

Reliability & Redundancy

How crucial is the air compressor to your operations? Can you afford downtime if there is an emergency break-fix situation? If the answer is no, you cannot afford the compressor to break down, it is probably smart to consider a backup compressor to provide redundancy and mitigate the risk of unnecessary downtime in production. While air compressors are highly reliable power sources, different machines carry different reliability standards when put into use for specific applications. It is important to understand the reliability differences, in regard to your operations, with each air compressor you are considering.

Maintenance Needs & Warranty

It is important to compare the ease and frequency of maintenance needed for your machine. Some compressors will require more frequent maintenance, while others may require less frequent maintenance, either schedule also carrying different costs. How long is your machine under warranty? Which parts are included under warranty? These are other important maintenance related questions to have answered before selecting the compressor that is right for your operations.

Durability & Lifespan

Different compressors have different needs for their environment. While some air compressors require clean, temperature-controlled environments, others are more durable and can handle uncontrolled temperatures and dirtier locations. The durability of a machine, and how well you abide by its environmental requirements, can also dictate its average lifespan. It is important to consider both factors when selectin an industrial air compressor for your facility.

Common Compressed Air Equipment Used

Rotary Screw Air Compressors

Rotary screw air compressors are a popular choice for a wide range of manufacturing operations. These units can run continuously 24 hours a day, 7 days a week. They boast benefits such as reliability, efficiency, lower maintenance, and quieter operations. These units are suitable for larger manufacturing operations that require continuous air supplies and/or have large demands to meet.

Reciprocating Air Compressors

Reciprocating air compressors provide a lower maintenance, cost effective option for smaller-scale manufacturing operations. Reciprocating compressors are great in facilities that do not require continuous air supply.

Air Dryers

Air dryers are essential pieces of equipment to remove excess moisture and ensure higher quality air gets delivered from the air compressor to its intended use. They come in a variety of makes and models. To learn more about finding the right air dryer for your operations, read our blog post EVERYTHING AIR DRYERS.

Inline Filters

Inline filters are another important piece of air treatment equipment, used to remove particles, aerosols, oil vapors, and other contaminants before the pressurized air is released for use. This enhances the air quality and prevents contaminants from entering your production process. They come in three different types including particulate filters, coalescing filters, and activated carbon filters.

Oil/Water Separators

An oil/water separator may be needed with your compressed air system to remove any contaminants, like oil, from the condensate that will be disposed of to ensure environmentally safe disposal.

Air Storage Tanks

Air storage tanks are great pieces of equipment to help meet fluctuating demand. These tanks can store already pressurized air so that it is ready for use at any time, ensuring consistent supply to your operations. Read our blog post, WHY ADDING AIR STORAGE TANKS IS BENEFICIAL TO YOUR COMPRESSED AIR SYSTEM, to learn more. 

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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• Air Compressor Dew Point 101
• Zorn Compressor Contractor Brochure
• Heat Recovery 101
• Air Compressor Applications in Toy Manufacturing
• How Industrial Air Compressors Are Different

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