Understanding Screw Compressors: A Complete Guide

A screw compressor is an air compressor that compresses ambient air in a closed housing using two rotating screw rotors. Screw compressors are now the leading industry standard in the field of compressed air generation and play an important role in all industrial plants as well as in the pharmaceutical and food industries where compressed air is required. Screw compressor technology is a mature technology that has been tried and tested for decades, which has been continuously developed and optimized over time.

The operation of a screw compressor is based on the principle of the positive displacement compressor.

Screw compressors are today's standard in industrial compressed air generation due to their efficiency, reliability and versatility. They can continuously deliver compressed air and are often more energy-efficient than other compressor systems, such as piston compressors. These properties make them the first choice for many applications, where a reliable, efficient and continuous supply of compressed air is required - around the clock.

The traditional screw compressor is specially designed for continuous operation (24/7 continuous operation) and proves its efficiency with a daily compressed air requirement, around the clock. This design proves to be extremely advantageous, especially in industrial applications.

For working environments with constantly changing compressed air demand, e.g., between different shifts, the VSD version of the screw compressor (with frequency control) can be used to automatically adapt production to the current demand for compressed air. In addition, a VSD screw compressor can also be useful for future expansion plans. Atlas Copco's extensive range always includes suitable models for the general requirements for pressure, volume flow and air purity.

Screw compressors offer a variety of advantages over other types of compressors:

• Efficiency: Screw compressors are extremely efficient due to their design and operation and can provide a constant flow of air.
• Compactness They are generally more compact than piston compressors of similar capacity and require less space.
• Continuous operation (24/7): Screw compressors are ideal for applications that have a constant demand for air because they can provide compressed air continuously.
• Low vibration and noise: Compared to other types of compressors, screw compressors produce less vibration and noise during operation.
• Maintenance: Due to their simple design and fewer moving parts, screw compressors typically require less maintenance and have longer service intervals compared to piston compressors.

According to the motto 'one man's joy, another man's sorrow,' the strengths of the screw compressor can also become a disadvantage depending on the situation.

• Screw compressors are designed for continuous operation. However, this means the other way around that other compressor types are more likely to be considered if demand is very low. In the event of extremely low occupancy, advice is highly recommended.
• Screw compressors are superior to many types of compressors in terms of energy efficiency. However, this is only the case with modern, energy-efficient models. Therefore, keep an eye on the power consumption of your screw compressor and find out about new technologies in the field of screw compressors at certain intervals.
• The screw compressor is often more expensive to purchase than, for example, the piston compressor.
  However, "the screw" scores points over time because the modern screw compressor often pays for itself after just a few years due to the energy savings. A piston compressor is an efficient sound insulation that can only be implemented at great expense, i.e., with the same sound emission, the screw compressor is usually cheaper.

Synthetic compressor oil is often used for screw compressors. These oils provide high thermal and chemical stability, which is required to operate under high pressures and temperatures. They are also able to effectively emulsify and remove water and contaminants, which is important for extending compressor life and minimizing the build-up of deposits. When purchasing compressor oil, it is important to pay attention to the viscosity level recommended by the manufacturer, as different compressors may have different requirements depending on their design and operating conditions. It is recommended to perform regular oil changes according to the manufacturer's recommendations to ensure optimal performance and service life of the screw compressor.

The service life of a screw compressor is affected by several factors. These include the quality of the materials and components used, the design features of the compressor, the operating conditions, the regular maintenance and the type of application and the operating hours per year.

A high-quality screw compressor that is made of sturdy materials and has a solid construction, tends to have a longer lifespan. Regular maintenance and care are also crucial to maximize the life of the compressor. This includes checking oil levels and quality, replacing air and oil filters, regularly checking and lubricating moving parts, and inspecting for signs of wear or damage.

Overall, a well-maintained and properly operated screw compressor can have a lifespan of decades, depending on the factors mentioned.

When planning your new screw compressor, it is crucial to take the operating conditions into account. A screw compressor is highly efficient and cost-effective, but it must be designed correctly.

For this purpose, it is advisable to contact the manufacturer and carry out consumption measurements with simulations during operation. This allows serious solutions to be developed with the most efficient compressor constellations. The standard consumption measurement should always be the basis for finding a solution. 

To help you make your decision to buy our compressor, we have put together a checklist for you here. This should make it easier for you to buy a screw compressor, taking into account current developments:

1. Define requirements: Define your requirements for screw compressor purchase, including pressure demand, air volume, operating cycle, and other specific requirements. Also consider how your compressed air demand will evolve in the future. Modern screw compressors offer certain flexibility in terms of future use, a feature that simpler models do not offer.
2. Determine power requirements: A free compressed air demand measurement with system analysis is the safest way to select the right, energy-efficient station. A theoretical summation of consumers will provide a risky result because of the large number of variables.
3. Set a budget: Set a budget that takes into account the initial cost, installation and possible additional expenses, such as maintenance and, above all, energy consumption to buy your screw compressor. The purchase price of the screw compressor plays a rather small role in the costs of compressed air generation over the years. The additional effort for energy-efficient models usually pays for itself very quickly.
4. Oil-free or not: Decide if you need to buy an oil-free screw compressor, depending on the requirements of your application and environmental regulations.
5. Define interfaces: Screw compressors also have smart functions that make them fit for the future. Take these into account when choosing the right compressor.
6. Size and space: Consider the space available for installation and choose a screw compressor that fits in your compressor room. Also note the volume development and the need for room ventilation and ventilation.
7. Compressed air quality: Determine the required compressed air quality for your application (e.g., dry, oil-free, particle size) and take this into account when you buy your screw compressor, with appropriate compressed air treatment.
8. Energy efficiency: Pay attention to the energy efficiency of the compressor when you buy your screw compressor and choose a model with low energy consumption to reduce operating costs.
9. Maintenance requirements: Consider the maintenance requirements of the screw compressor you want to buy and schedule maintenance services accordingly. 
10. Warranty and support: Check the manufacturer's warranty terms and available customer support when you purchase your screw compressor to ensure you get assistance in case of any issues.
11. Installation and commissioning: Carefully plan the installation and commissioning of the screw compressor and make sure that all necessary precautions are taken when you buy your screw compressor.
12. Safety: Be aware of the safety aspects when installing and using the screw compressor and ensure that all safety standards are met when you purchase your screw compressor

Atlas Copco is a renowned screw compressor manufacturer known for its high-quality products and innovative technology. Atlas Copco offers a wide range of screw compressors suitable for various applications and industries.

As a leading manufacturer of screw compressors, Atlas Copco started producing piston compressors in 1904. Since then, the company has played a key role in the advancement of compressor technology to meet the changing needs of the industry.

Atlas Copco's screw compressors are characterized by their high efficiency, reliability and durability. They are suitable for a wide range of applications, from small workshops to large industrial plants. Atlas Copco also offers tailor-made solutions and supports its customers in selecting the optimal compressor for their specific requirements.

With a strong focus on energy efficiency and the development of technologies such as VSD technology, Atlas Copco is a pioneer in the industry.

In addition, Atlas Copco offers comprehensive customer service worldwide, including maintenance, repair and training, to ensure that compressors always perform optimally and customer productivity is maximized.

Overall, Atlas Copco is a prime choice for businesses that need a reliable and efficient screw compressor.