When working with applications in the machine industry, it's worthwhile researching the right heavy-duty compressor. Doing so will help ensure you're investing in equipment that can run for long periods while minimizing energy costs.
In addition, you'll want an air compressor capable of withstanding dust and other atmospheric debris. Of course, for maximum lifespan, we recommend maintaining optimal conditions in your facility.
That said, there are heavy duty compressor models available that can meet all the needs stated above. In particular, an oil-injected rotary screw air compressor works well for the following applications (among others).
Pneumatic tools for assembly lines
Actuation of robotic arms and automated systems
Precision cutting
Milling and grinding (removing debris)
Clamping
Paint spraying and surface finishing
Mist lubrication
Material handling, conveying, and packaging
In this article, we'll further explain our recommendation above to meet the varying needs of the machine industry. Read on to learn more about what to look for when comparing compressed air equipment.
Considerations for compressed air in the machine industry
Flow and pressure
When selecting any compressor, it’s important to know your air demand and usage patterns. Your pressure and flow requirements, for example, will determine the right compressor size. A properly sized compressor will keep your investment costs in check and can significantly lower your energy costs.
Different tools require different pressure levels. For instance, clamping may need a lower pressure than milling. Your air system pressure must be set to meet these different needs without being unnecessarily high. Keep in mind that lowering system pressure by just one bar can mean 7% energy savings.
Consistent pressure is crucial for tool performance, robotic actuation, and precision processes. Look for pressure regulators to ensure stability. Variable speed drive compressors limit fluctuations with their stable, narrow pressure band.
100% duty cycle
If you rely on an uninterrupted supply of compressed air (as is typically the case in the machinery industry), a compressor that offers a 100% duty cycle will best suit your needs.
Air quality
Compressed air can contain three types of contaminants:
- Moisture can damage tools, affect paint finishes, and cause corrosion in pneumatic systems. Aftercoolers and air dryers, which often can be integrated into your compressor, remove moisture from your air system.
- Oil contamination can affect the quality of sensitive applications such as paint spraying and precision cutting. This can be avoided by using oil-free compressors or oil-injected models with high-quality filters.
- Dust or debris can clog tools and damage certain equipment. Adding particulate filters helps keep your air clean.
Each industry must meet its air quality requirements as defined by the ISO 8573-1 standard. Most machine applications don't demand ISO 8573-1 Class 0 air quality for moisture, oil, or dust. An oil-injected compressor with air treatment equipment such as dryers and filters is compliant with most machinery air standards.
Compressor type
In addition, you'll need to choose between compressor types, including piston and rotary screw. While piston compressors are durable and relatively low cost, they aren't always the best choice. For example, many require cool-down periods, interrupting your production
Rotary screw machines, on the other hand, tend to be better suited for the machine industry. This is because they can run for long periods and come with efficiency benefits. The latter is also because of VSD technology available for rotary screw compressors.
When compared to fixed speed rotary screw and piston machines, VSD rotary screw equipment can offer double-digit energy savings
The right heavy duty compressor
Since energy costs make up to 80% of owning and operating an air compressor, efficient equipment pays off. With that, a rotary screw compressor with VSD technology will likely save on operating costs. This is because piston equipment typically can only run at full speed. By comparison, VSD screw equipment changes motor speed to meet demand. This means minimal energy consumption when demand is low.
One other benefit of using a VSD compressor is the potential for dust resistance. For example, the Atlas Copco GA VSDS machines are IP54-protected from dust and dirt. This can greatly impact overall lifespan and reduce maintenance when working in the machine industry.
Additionally, GA VSDS rotary screw compressors are up to 60% more efficient than fixed speed machines.
After selecting the right compressor, adding energy recovery is the most effective way to lower your operational costs significantly. It captures the heat your compressor produces to feed it to applications (such as HVAC) that need heat. It's a true win-win solution that essentially lets you use your compressor’s energy twice.
It’s also important to note that typically only 10-30% of the compressed air is effectively utilized. Most is lost through leaks, inappropriate usage, and other inefficiencies. Therefore, optimizing compressed air systems by addressing leaks, adjusting pressure settings, and implementing efficient equipment can lead to substantial energy savings.
Finally, regular maintenance of compressors, filters, and dryers optimizes the efficiency of the air system and prevents downtime.
We're here to help
Although this article doesn't get into each application, we hope it helps you choose the right compressed air equipment. When selecting a heavy duty compressor, we can point you in the right direction. This includes our latest VSD rotary screw models. We're available to answer any questions you may have. Feel free to contact our team at any time.
