Compressed Air Technologies

Despite years of warnings — and the development of OSHA standards — there are still many dangerous compressed air blow wands in service at facilities throughout the world. Countless injuries and even deaths could have been prevented if safer devices were used or the blowing eliminated altogether. Fig. 1 shows a wand used to clean […]

The 2022 edition of VMAC’s State of The Mobile Compressed Air Industry Report has been released, sharing fascinating insights from mobile air users. “We are pleased to release VMAC’s latest research on the mobile compressed air industry,” said Tod Gilbert, President of VMAC Global Technology Inc. “There is a lot of uncertainty with global events […]

If you are shopping for a refrigerated air dryer, it is a good idea to consult the Compressed Air & Gas Institute (CAGI) published data from the manufacturer before you buy. If you buy a non-cycling air dryer, the unit will consume about the same power no matter what — even if the associated air […]

Compressed air is often disregarded as a common utility in factories, but risks are high with pressurized air running through pneumatic hoses. Learn how to use these tools safely. Contributed by Mindy Schoeff, Marketing Communications Manager and Ron Hibbler, Applications Manager, Proportion-Air Compressed air is nearly ubiquitous in factories. It’s part of the power behind everything […]

A recent question received by email: I need some help from you regarding air leak calculation. We just purchased a new air leak detector that calculates leakage flow.  We have high air leakage in our LPG bottling plant and our leak detector showed a flow of 9130.2 L/S. If we convert this to CFM then it will total […]

By Ron Marshall A wood products manufacturer decided to save money by hiring a small service company to maintain its compressors. The company had minimal experience in repairing compressors, but agreed to do the job. The company didn’t have parts available to replace the faulty controls on the two screw compressors — so they did […]

By Ron Marshall A building products company had a compressed air system that featured one large 1,500-cfm compressor and three smaller ones. The compressed air flow had grown to a point where the large compressor could only be turned off during shutdown periods; when it was turned off, the plant pressure would collapse. The large […]

When a 40 bar turbo compressor situated within an internationally renowned British-based producer of soft drinks broke down, it was faced with two choices: repair or reconfigure. Choosing the latter, the producer found that the old proverb ‘as one door closes, another opens’ proved true. Founded in the late 1930s by an entrepreneurial chemist, Britvic […]

A press operation used a pulse of compressed air for cleaning operations for 10 seconds, once every 10 minutes.  The compressed air flow to the press during the cleaning was 400 cfm, a quite significant flow, and data logger measurements of the air compressors found that each time the blow happened, a 150-hp compressor would […]

Contributed by Mike Kreklau, Technical Sales at Tsunami Compressed Air Solutions Downtime and inefficiency don’t have to be your production line’s worst enemy. You want shop equipment that comes with no strings attached — no downtime and no maintenance. Maybe that’s a pipe dream, but there are ways to fix many air-related symptoms of an inefficient […]

The operators at a lumber mill were having production problems in two of their machines.  Annoyingly, critical sensing eyes were getting blocked by occasional pieces of bark as the logs went by.  After enduring this for quite a while the maintenance department finally took matters into their own hands. The plant had a welding department, […]

Are you still using open ended compressed air blowing?  Are these blowers simply controlled by a ball valve?  Did you know these tools can turn into dangerous uncontrolled projectiles if accidently dropped when the valve is wide open? They cause noise pollution and present a risk of eye injury when chips of debris are sent […]

Many industrial sites measure their compressed air quality, or think they do.  When asked to show the dew point of a system with refrigerated air dryers, the compressor operators will typically point to the air dryer display, not knowing that the reading is not really dew point, but the temperature within the air dryer itself.  […]

A large foundry had four large 200-hp air compressors that were water-cooled and were having overheating problems.  The units were capable of inlet modulation control,  where the inlet valve of the compressor closes off the intake to control the output flow.  Use of this control mode reduces the flow output of the compressors and the […]

A building products company purchased a compressor with 1,520 cfm capacity to help with the increased load after a plant expansion. Various dryer sizes were available, but one sized at 1,600 cfm was selected, rather than choosing the next size up, to save purchase costs. Shortly after installation, the production machine operators started complaining about […]

During a compressed air assessment, a service provider was reviewing the total capacity of the storage receivers for his report.  Having adequate capacity helps make the compressors run more efficiently and saves energy.  During his checks, he spotted a strange color on one receiver safety valve.  On closer inspection, he noticed that the pressure relief […]

A facilities manager at a building products plant attended a compressed air efficiency seminar sponsored by his local utility. He learned about optimizing air compressors, filters, dryers, and piping. He discovered how to arrange to have a baseline taken of his compressed air system to assess its efficiency. He discovered the excellent savings he could […]

A building products company was having problems with pressure loss across its main dryers and filters.  Data monitoring showed differential pressure reached as high as 18 psi, causing a large sag in plant pressure, which during peak times caused production outages.  An investigation revealed that the dryer was low on refrigerant, causing the unit to […]

By Ron Marshall What is my compressed air’s electric bill percentage? This is a difficult question to answer, because rarely are there any energy meters installed on typical compressed air systems. But there are some hints if we do some research. Years ago, the USDOE did a detailed study of motor systems and found that […]

A pump manufacturer implemented a new compressor control strategy that was intended to save energy.  The c0mpany had three compressors running — one fixed speed unit and two VSD style units — and found after studying the system they only needed two compressors to feed the load.  Savings could be gained by automatically turning a […]

A common question posed to compressed air experts is “What component should I adjust to get my compressed air system running more efficiently”? The common answer is, “You should adjust that thing located between your ears.” Compressed air professionals commonly find poorly maintained and incorrectly adjusted equipment when they visit their customers’ compressor rooms.  And […]

An industrial component manufacturer had a system of five compressors located in an interconnected system spread between two buildings. The system pressure of the system was constantly running near 120 psi because of some critical high-pressure applications. Most of the production machinery was rated at 90 psi pressure. The facility manager was sure something could […]

A seed cleaning company was looking to expand its operations by purchasing  new compressed air using equipment. Plant people spoke with the sales engineer — who informed them that each proposed cleaning machine required a minimum of 50 cfm of compressed air.  Doing quick addition in his head, the engineer calculated they would need a […]

Industrial Internet of Things (IIoT) technologies are placing compressed air systems front and center, despite usually being in the shadows. Contributed by Graham Coats, Sales Director at CMC Until very recently, the air compressor has been nothing but a workhorse; a key tool in the manufacturer’s toolbox, certainly, but one that’s kept away in the […]

Tsunami Compressed Air Solutions has four new products ready to order for the new year – adding more capacity and customization to its product line. Tsunami’s new products include: an 80 cfm Pure Series Dryer, an 800 cfm Oil Coalescing Filter, a 120 cfm Activated Carbon Filter, and a pneumatic drain option for the Tsunami […]