Simple Ways to Reduce Your Compressed Air Costs?

Air compressors use considerable volumes of energy during a typical work cycle. When you add up all the expenses of operating a facility, any savings can help you boost your bottom line. With air compressors, savings come down to efficiency, which depends on a steady maintenance regimen. The following 13 ways to reduce compressed air costs can help you increase your productivity, boost your earnings and prevent costly repairs and system downtime.

1. Turn Off Your Air Compressor

Air compressors use considerable volumes of energy during a typical work cycle. When you add up all the expenses of operating a facility, any savings can help you boost your bottom line. With air compressors, savings come down to efficiency, which depends on a steady maintenance regimen. The following 13 ways to reduce compressed air costs can help you increase your productivity, boost your earnings and prevent costly repairs and system downtime.


One of the easiest ways to lower compressed air costs is to simply turn your compressor off during the hours when you do not need it for any of your applications. To a lot of people, this might seem like a piece of anti-advice. After all, this article is about how to lower compressed air costs and be productive with pressurized air. How would shutting off the compressor help you achieve that goal? The thing is, a lot of people keep their air compressors idling during off-hours, oblivious to the fact that this wastes energy.

Think of it this way. A calendar week consists of 168 hours. Unless you actually use your compressor for processes that run nonstop, 24/7, there is no reason to have your compressor running every hour around the clock. If you only use the compressor for eight, 10 or 12 hours per day, five days per week, you would only need to have the compressor on between 40 and 60 hours in a given week. By cutting the hours of usage down to a typical working week, you could cut your energy consumption down by two-thirds and see significant savings in your subsequent energy bills.

2. Repair Existing Leaks

To save money on compressed air costs, it is crucial to eliminate air leaks as much as possible. With air compressors, four-fifths of the energy consumed in a given cycle turns to heat, and only the remaining 19 percent yields air power. When leaks and other performance issues plague the compressor, the overall efficiency drops even lower than that one-fifth level. It is, therefore, essential to inspect your compressed air system for leaks regularly and perform maintenance when necessary.

Most leaks are hard to detect because they are either located in hard-to-access spots or the rupture is not large enough to be audible at arm’s length. Depending on the scope and magnitude of your operations, the costs associated with air leaks could spill into the four- or five-figure range each year. The most effective way to reduce leaks is to use an ultrasonic leak detector, which can detect some of the smallest and faintest leaks. With a leak detector, you can spot and remedy leaks in their formative stages before they expand and lead to costlier problems.

3. Stop the Formation of New Leaks

Consistently achieve lower compressor energy costs, you must perform anti-leak preventative maintenance regularly. During each inspection, leave no stone unturned in your efforts to prevent the formation of leaks. When it comes to stopping leaks, you must look at various parts of the system, both inside and out, because various problems can result in new leaks.

The first place to check is the pipes, which could be vulnerable to cracks if corrosive elements are allowed to deposit along the length of a given pipe or any of the connecting points. If you spot dust particles or sludge around the piping, clean these spots as thoroughly as possible. To keep each surface in optimal condition, you must keep each pipe clean and dry.

During these inspections, check the filters and drains to ensure that no dust or water accumulates within the system. When mist and dirt get trapped within the compressor and deposit on various internal parts, corrosive gunk can take hold and lead to rust, leaks and system strain.

4. Lower the Air Pressure

Even when your system is free of leaks and dirt, you can cut compressed air costs even further by reducing the pressure to the levels required for a given operation. At many facilities, pressure levels are set to maximum thresholds to accommodate the highest-pressure applications. The trouble is, these high-pressure tools and applications might only account for a fraction of the air-powered arsenal.

If you only use high-pressure tools on a part-time basis, consider the possibility of separating those tools from the rest of your equipment. This way, you could run your compressor at medium pressure and save energy through most of your working hours and only increase the pressure when necessary.

If you operate a large facility with multiple compressors, designate each machine for different pressure levels. For example, if you have a range of lower- or medium-pressure applications and only one or two that require high pressure, you could save energy by moving those latter applications to a second compressor specifically designated for such tools.

5. Inspect the Drains, Replace if Necessary

While condensate drains perform an essential task for your air compressor, the feature itself could be a huge drain on your system if it malfunctions without anyone noticing. On air compressors with timer drains, the drain valve will automatically open each time the timer goes off. If the machine is inactive when this occurs, the timer drain will start up the motor for a short time. Consequently, the drain could often inflict excess wear and tear on your system, just so the drainage process can occur according to schedule.

Further problems could arise if the timer drain gets stuck in the open position. Depending on the placement of your air compressor and the maintenance schedule of your staff, an open drain door might go unnoticed for several weeks or months. That whole time, compressed air will inevitably leak from the system.

To get around this problem, use a zero-loss drain. This way, your system will not be vulnerable to air loss each time you drain the system. By investing in a zero-loss drain, you can save in the long run by preventing the air loss and maintenance costs that will mount over time due to the problems associated with timer drains.

6. Reconsider the Piping Setup

The piping for your air system should be wide enough to allow optimal flow and reduce pressure drop. At the same time, pipes should travel the shortest possible distance to reduce the length of flow, as lengthy flow increases the possibility of pressure drop. With wider pipes, you can cut pressure drop in half because the air can travel faster and retain its original pressure.

Pressure drop is liable to increase when the routing is lengthy and complicated. The longer each flow must travel, the more the pressure drop will be by the time the air reaches its end-point destination. If the pipes are changed in a way that doubles the flow, the pressure drop could increase four-fold. Consequently, your pneumatic processes would be rendered weaker, and the system overall would be less efficient because of tight, lengthy piping.

In recent years, piping has changed on newer compressed air systems. If your current piping was used years earlier on a smaller compressor, consider a new arrangement. If your pipes are smaller than the outlets on your compressor, trade up to a new set of pipes that are wider in diameter. Rather than complicate matters, arrange your pipes so that the flow is wide and as short as possible.

7. Clear the Filters and Replace When Necessary

To further cut compressed air operating costs, clean the filters throughout your system on a regular basis. On each unit, the filters play a critical role in the process of the system by capturing dust and dirt from the incoming air. This way, the ambient air is free of air-bound particulates by the time it enters the pressurization chambers. Without the filters, the pressurized air would likely be contaminated and rendered far less effective for pneumatic applications. Moreover, dust and dirt would filter through the air compressor and accumulate on various internal parts.

Depending on the volume and frequency of your operations, each filter should be cleaned on a weekly or monthly basis. Make sure that all dirt is removed before you restart the compressor. Additionally, clean any secondary filters, such as air-line or point-of-use filters situated outside the compressor room or away from the actual units. When a filter appears worn or soiled with residue, change out the filter with a matching replacement.

8. Conduct and Schedule Maintenance

When it comes to the operation of your system, one thing is certain — maintenance amounts to savings on compressed air operating costs. To maximize the functions of your air compressor, you must inspect the unit on the outside and inside periodically. In addition to the pipes and filters, you should regularly inspect the motor fans, drip tray, belt and lubrication.

The fans in your air compressor perform a crucial function by lowering the heat inside your unit. To keep the fans fully functional, check the blades for dirt or lint. If one of the blades appears dull or cracked, trade out that fan for a newer duplicate.

Each time you open up the air compressor, inspect the belt to make sure that it has the proper flex to function properly. Give the belt a slight pull to test its elasticity and run your finger across the side for signs of cracks or dullness. When you check the lubrication, make sure that it has the proper color and viscosity. If the machine has been excessively hot, the lubrication could melt and leave the internal parts vulnerable to grinding and rust.

9. Identify and Eliminate Wasteful Uses of Compressed Air

An engineer who knows how to save on compressed air costs will work to eliminate wasteful uses of pressurized air. Regardless of the size of your facility, it is crucial to know the pressurization requirements for the applications at hand and the amount of energy needed to make it all possible. Otherwise, extraneous uses of energy could eat into your profit margin.

In some cases, various minor acts of compressed air usage can amount to wasteful behavior. For example, if pneumatic blowers are used by factory floor personnel to dust off tables and shelves, air power is being consumed for a function that could just as easily be performed with manual brushes.

In other cases, extraneous compressed-air usage can quickly become a costly habit. For example, if air blowers are being used to cool the interior of an industrial facility, you could be faced with soaring energy costs over a function that would be much better achieved with fans or an air conditioning system.

10. Rearrange the Air Receivers

In a compressed air setup, the size and placement of the air receiver is a major determining factor in the overall operating cost of the system. For each successive pressurized air supply, the air receiver functions as a placeholder between the compressor and the system at large. Within the air receiver, the pressure is modulated to suit the demands of the application at hand.

In some factories, technicians place the air receiver before the air dryer. This way, lingering traces of oil and condensate are removed from the process before it reaches the dryer. The downside to this arrangement is that the receiver is forced to hold denser supplies of air. If the demand surpasses the capacity rating, the dryer might get overloaded and increase the dew point pressurization.

The other option is to place the receiver after the dryer. This way, spikes in demand are received with dry air. For protective purposes, the ideal arrangement is to affix the supply side with two receivers. In this arrangement, the first receiver controls condensate dropout while the second handles varying demand levels.

11. Choose the Right Dryer and Filter

The importance of drying pressurized air is generally a misunderstood concept, even among people who mostly understand how to lower compressed air system costs. Consequently, the systems put in place for this purpose are often inefficient. One of the most frequently asked questions about filters and dryers concerns whether desiccant or refrigerant types are best. The question is usually followed by further inquiries regarding regulators, lubricants and filtration levels.

12. Get a Professional Tune-up

Before these questions can be answered, the applications of your compressed air system must be taken into account. For example, the level of your drying needs could depend on whether you operate in a humid environment. That said, certain principles apply in all cases. For starters, never allow pressurized air to dry beyond the required level of the application, as doing so will make your operations more costly. The more efficient option is to first use a refrigerant dryer and only apply further drying on an as-needed basis, as determined by the application. To avoid additional pressure drop, limit your use of filters to the bare necessity.

One of the easiest ways to save money on compressed air energy is to pay for a professional tune-up of your air compressors and peripheral parts. When you hire a third-party maintenance technician to come to your facility, that person will likely spot issues that your in-house staff may overlook. Professional maintenance techs have inspected hundreds of different air compressors and know about all the common mistakes that users make with these machines.

A professional technician will come to your facility with equipment and tools to evaluate and tighten up your system in all the weak spots. If your connectors are loose, the technician will tighten these spots and run a test on the compressor to verify that the leaks have been sealed. If your compressor is losing oil, the technician will diagnose the problem and rectify the situation, whether this involves a new compartment or a new set of fasteners.

13. Select the Right Air Compressor

Anyone who really knows how to save energy in compressed air systems will stress the importance of choosing the right type of compressor for a given set of applications. If your operations are large and high-volume, you will need a different kind of compressor than the type used by companies that specialize in delicate products and vice versa. In any case, the four main compressor types are defined by the following attributes:

Who we are and how Ash Air can help your business!

Ash Air has been around in New Zealand since 1979, and we’ve grown into a nationwide company with international support and a reputation for quality and reliability.We look after all things compressed air for your business!

Ash Air's range of Chicago Pneumatic, Alup, Pneumatech, and Quincy compressors are used extensively around the world in industries ranging from oil and gas to food, automotive and farming, and we bring you these world class compressors here in the land of the long white cloud.Our technicians are compressed air equipment experts and are dedicated to addressing customer needs. Supported by a 13 locations nationwide, Ash Air offers one of the widest selections of compressed air equipment and parts available today in New Zealand.

Reliability and Efficiency

With Ash Air compressors, you can count on reliability and high performance for even the most demanding applications. We focus our efforts on the following:


Talk to the team today:  CONTACT US CONTACT US


Other Blogs


Just like any other equipment, a compressed air installation also requires the necessary maintenance work during its entire lifespan. Even though maintenance costs are only about 5 to 10% of a machine's annual operating costs, failure to budget for maintenance can have potentially disastrous consequences. …


The air dyer is one of the most ignored cooler in the system. A dirty condenser will cause water in the lines, or worse it will cause complete dryer failure. …


Using nitrogen is not about fully replacing CO2, but it can reduce their consumption of CO2 by close to 70%. Using nitrogen is about sustainability. Creating your own nitrogen is easy and will reduce the use of a greenhouse gas, which is better for the environment. It will also save you money as early as month one adding that savings to your bottom line. …


A question that is occasionally asked by our customers to Ash Air is 'what is the cost of compressed air?'  This article looks at the product costs involved with compressed air, as well as minimising the energy cost of compressors and cost allocation. When looking at these factors, we need to realise what causes dropped efficiency of your compressor, leading to increased costs of compressed air. …


You may have great fall protection measures in place to keep employees safe when working at height, but what about their co-workers below? Dropped tools and other falling objects are a major hazard – and one that isn’t always fully addressed.  …


Providing a safe working environment for operators is essential, especially when using pneumatic tools and compressed air. If there is a failure in the air network and the hose is not adequately clamped, the resulting whiplash could be devastating. Failure to follow best practice can result in injuries, associated production downtime and decreased productivity. …


A common questions asked is why do I need an air dryer for my compressor? Typically, air compressors produce water, and although the water can be drained, there can still be aerosol and vapour droplets that are present. This is because water cannoet be compressed. Water can damage your compressor by corroding the valves, pipes and machinery controls, which will cost you time and money to resolve. In the long run, the cost of a new compressor is a small price to pay compared to the loss of production that could potentially arise due to water damage in your compressor.





…


Air compressors can fail for an assortment of different reasons: Normal wear and tear, lifespan and age of the unit, poor maintenance, power surge, install issues are just a few the come to mind. Check out this blog to find out our top 7 tips to ensure your compressor is looked after!  …


That cold, rainy, and in some places icey New Zealand winter is upon us, and with the following air compressor tips, your air system will be prepared with the preferred temperatures, despite the weather outside. Regardless of whether or not it actually snows or freezes up where you live, most winterisation service recommendations are also basic, solid maintenance procedures that will help extend the life and operational efficiencies of air compressors regardless of whether you live in Queenstown or Northland. …


If you're wondering what an air compressor actually is, you've come to the right place. Simply, air compressors convert power in to air that is pressurised which is then used to power air tools such as spray guns. Air compressors are used in a wide range of applications, so naturally if you want one that will be designed for spray painting your vehicle, you want a compressor specifically made for spray guns! This way your compressor will be able to provide the right amount of power to perform the job. …


Compressed air plays a fundamental role in industrial activities. Depending on the type of application, the energy cost of producing compressed air can be very high. Below are some tips to save on you compressor bill. …


Air Compressors are essential tools in a variety of industrial settings. No matter what industry you are in having a reliable air compressor can be a crucial part of getting the job done efficiently. However, like an investment, air compressors require upkeep and maintenance, and eventually will need to be upgraded. But how do you know when it’s time to upgrade your air compressor? Here are some things you need to consider. …


When it comes to laser cutting and other industrial processes, the choice of assist gas is crucial in achieving optimal results. Nitrogen and oxygen are commonly utilized as assist gases, each with its own unique properties and applications. Understanding the characteristics of both gases, will help you to make an informed decision to ensure precision, efficiency, and cost-effectiveness in your operations. …


Mobile air compressors are portable, towable compressors particularly useful for applications that suit the construction and roading industry! You'll often see a mobile compressor being used for sandblasting, irrigation blow-outs, and for quarrying tools such as pneumatic block cutters and rock drills.   …


Did you know that Chicago Pneumatic helped man land on the moon? Notice in this photo of the Apollo 11 landing what appear to be "soccer balls" on top of the capsule. They were inflated through a compressor specially developed by Chicago Pneumatic for NASA. …


Your company purchased an air dryer for your compressor, now where should you install it? One of the most common things we see in the industry are air dryers being stored on top of the compressors. Seems like a wasted space not being used on top of the compressor, right? Wrong. …


When using air compressors, there are many variables that are integral to the quality and effectiveness of your compressed air. When dryer air is necessary, being able to constantly and accurately monitor dew points can be a critical factor to your operation. …


Compressed air plays an integral role in breweries both large and small around the world. From start to finish, all details in the brewing process are managed in fine detail and having the right air compressor is no exception. …


We Kiwi's love our Coffee! Coffee, like all other food & beverage products, must go through a preservation process to keep the beans fresh during storage and packaging before they reach the consumer. Coffee that is not properly stored after it is roasted will lose a large amount of carbon dioxide, which lessens its' flavor and speeds up the staling process. One of the most common ways to preserve the freshness of coffee is the use of nitrogen gas. Learn more here: …


Air compressors are helpful for an enormous range of applications such as air filling, packaging, tools, HVAC control, and more! One possible drawback is the amount of electricity they use; air compressors can be a huge drain on energy if used ​inefficiency...  …


We get it, buying an air compressor is a big financial decision. And now we are suggesting that you need two air compressors, not just one. Ask yourself one question- Can your business still run if your air compressor goes down? …


It’s no secret – air compressors are excellent sources of energy. Not only do they power essential manufacturing elements and applications, but the heat generated as a result of the compressed air processes can be used as a byproduct that offsets other energy costs. However, there’s another form of energy that is also a consequence of the air compression process – sound. …


The emergency stop, "e-stop", is for true emergency situations only. When hitting the e-stop, all power is halted from the machine and the unload process isn't achieved. The emergency stop button is intended to help with possibly hazardous situations that are developing. Common conditions of having to use the e-stop is the misuse of the equipment in ways that weren’t intended, predictable failures not addressed or failing to consider all the foreseeable uses of the compressor.
…


We've put together a list of tips for working safely with air compressors in your environment! We recommend that you always read owners manual before running your compressor. The number one cause for repairs and personal injury is improper use. You've got to remember to use eye protection and hearing protection when operating your air compressor and try to avoid using air compressors in a wet area.  …


Air Compressor Installation Tips Installing Your Reliable Air Compressor

So, you've just bought an efficient and reliable ALUP air compressor? Welcome to the world of compressed air. As your partners in compressed air, we will continue to assist you along your journey. We have provided air compressor installation tips to ensure you get the most out of your air compressor.  …


Air dryers remove any condensation from the air compressed by your air compressor. Questions about them? Find answers to the most frequently asked questions here. …


Power tools are a key to productivity in the oil & gas or the metal working industry. Maintenance and production tasks must be carried out efficiently, however intensive use of vibrating power tools, such as grinders, can expose operators... …


Selective soldering with nitrogen is an essential process in the production of printed circuit boards (PCBs). It is used for bonding components to PCBs that could otherwise be damaged if exposed to a lot of heat. Another area of application are mixed-technology circuit boards with layout constraints.  …


Hydrogen is becoming increasingly important as a promising clean energy carrier – especially with a view to a more climate-friendly future. But have you ever wondered what hydrogen actually is and how it is produced? In this article, we look at the basics and technologies used to produce hydrogen and what makes hydrogen a special element. …


Your passion is vinification, ours is air compressors. 

Compressed air accounts for a large amount of energy consumption in the wine production process, especially in the production of grapes. A big part of wine-making is a result of the work of equipment and is dependent on its efficiency. An air compressor should be located in well ventilated, shaded areas, out of direct sunlight. This includes the inlet for the compressed air system which should be located away from heat sources such as the compressed air outlet, refrigeration or air conditioning plant and equipment. …


Cutting, shaping, drilling, and finishing, compressed air is critical for any machine shop. Shops rely heavily on the compressed air system to assist in a variety of operation processes. Commonly the parts produced are used in the machine industry, car industry or even the aircraft industry. A traditional workday in a machine shop requires the use of air compressors to generate an intermittent or continuous source of pressurized air. What machines commonly require compressed air in the shop? …


Variable Speed Drive compressors  are a game-changer in the world of compressed air. These compressors automatically adjust their operating speeds to match the real-time demand for compressed air. It's an important feature, especially when it comes to energy savings. Surprisingly, the electricity consumed by a compressor can account for the largest portion of its total cost of ownership, not the initial purchase price. On average, VSD technology can reduce energy costs by 35% to 50%, which translates into significant saving …


When an industrial application calls for a steady supply of quality air, more and more users are turning to rotary screw compressors. Their efficiency, reliability and versatility make them a great choice in these cases. But there are countless applications and many different types of rotary screw air compressors. So which one is the right one for you? …


Your tool is stalling, or is not working to its expected performance, and you find yourself asking ‘why is my angle grinder spinning too slowly?’, or ‘why has my pneumatic grinder stopped working?’, read on. …


Lighting tower reminds night, but also refers to diesel engine. In turn, night reminds us of silence, which is not exactly what we associate with an engine... With urban centers becoming increasingly dense and legislation increasingly strict about noise pollution in construction sites, keeping decibels to acceptable levels has been the great challenge of the main construction equipment manufacturers. …


In today’s world of increasing environmental awareness and the drive for sustainable practices, industries are actively seeking innovative solutions to reduce energy consumption and minimize their carbon footprint. If your business uses air compressors, focusing on energy recovery in air compressors is one area to pay attention too.  …


Did you know that 70% of the total cost of compressor installation consists of energy costs?

There are many reasons why saving energy is important for your business as it helps you in many ways to make your business more efficient as well as providing you with many different forms of value. Ash Air's range of Alup products can help you become more energy efficient to help reduce energy bills, reduce your costs and comply with all environmental legislation. …


Exactly what is compressed air? Where does it come from? What is it for? When we compress—or squeeze—air into a small space, we call it compressed air. When humans discovered the ability to compress air, civilisation made a huge leap forward. The reason? Compressed air opened the door to all kinds of new production methods.  …


Compressed air system leaks are indeed a big source of energy waste. Leakage in piping systems have been shown to exhibit leaks of up to 25 percent of the total energy costs. Addressing leaks is one of the first maintenance steps a facility can take to reduce energy costs. …


Think about efficiency for a minute. Every year with constant innovation, things are becoming even more efficient. Everything from electronics to industrial machinery are being developed to get more done faster while using less power. …


The air surrounding us is a mixture of fry air and water vapor. The amount of water in the air depends on the temperature and volume of the gas. The higher the air temperature, the higher the air's ability to absorb more moisture. Find out about compressed air humidity here. …


Investing in an on-site industrial gas generator is a great way to reduce your environmental footprint and your operating costs. Once you have taken this important step, there are some other things you can do to maximize your gas generation energy savings. Here are seven of them. …


For many businesses, preserving energy and becoming more sustainable have become top priorities. That not only saves them money but also makes them more competitive in the future, when demand for “green” products and services will only increase. Not just because governments mandate greater sustainability but also because customers expect it. …


While you relax and read this, do you see an electronic appliance around you? Wondering how could you relate to the current read? We got you! Compressed air is all around, in the electronic appliances you use right now. …


There are many contaminants that can threaten your compressed air system, but moisture is among the most prevalent. You may be thinking, but it’s just water, but water can have a devastating impact on your compressed air system, your production equipment, and your end product. The best way to prevent moisture from contaminating your compressed air is with a dryer. …


Compressed air can be one of the most expensive forms of energy for manufacturing plants, often using more energy than other equipment. One horsepower of compressed air requires eight horsepower of electricity. With many air compressors running at efficiencies as low as 10%, there’s often plenty of room for improvement. Fortunately, 50% of compressed air systems at small- to medium-sized industrial facilities have opportunities for low-cost energy conservation. …


As easy as it would make all of our lives, vacuum pumps are far from being “one size fits all”. Not only do you have the size to consider when choosing a vacuum pump, but more importantly type. I will briefly touch on some of the advantages and disadvantages associated with each vacuum technology we deal with. This should give you a better understanding of where to begin your search... …


AIRnet offers moisture-eliminating drop fittings called Quick Drops! Quick Drops make “drop-tees” obsolete, removing the need for extra parts and pipe, while saving time and money. …


Proper compressor installation and commissioning helps ensure trouble-free startup and long-term reliability. Thorough inspection and critical review during each phase of the installation process eliminates “built-in” deficiencies or problems which c... …


Price is an important consideration when choosing a tool for metalworking applications, but it alone should not be the deciding factor. Other things also contribute to the total cost of ownership, performance, and, ultimately, the overall productivit... …


Are you faced with the decision of whether to switch from purchasing bottled nitrogen or oxygen to on site gas generation? In that case, the decision is easy. You should! Lower costs, the right purity, less transportation emissions, improved safety, no logistics headaches. In all of these areas, on site gas generation is the superior solution. And making the switch is easy. All you need is a gas generator and a supply of compressed air. …


Did you know that one of the largest costs for industrial manufacturers is compressed air? That’s right – anywhere from 12% to 40% of a facility’s total energy costs come from its compressed air installation. This means that finding innovative ways (no matter how small) to increase compressed air efficiency can amount to big savings over the long run! Items like leak elimination, air audits, reduced pressure bands, and reducing unloaded running hours are some of the most popular ways to decrease energy usage – but there are many other actions that you can take. Read on to discover additional ways to reduce your costs and make sure your compressor system is running as efficiently as possible! …


A properly sized and designed piping system is a necessary component of any distribution compressed air system. Without this key component in place, the delivery of air from the compressor to the specific points of use will be inefficient and costly, both in the short term as well as in the long term. Let’s look more closely at how to size your compressed air piping system to ensure minimal pressure loss while maintaining maximum efficiency. …


Potential for growth of micro-organisms in a compressed air system is tied to the moisture level (dew point) of the compressed air. In simple terms, if there is moisture in your compressed air, microorganisms such as mold and bacteria have the environment they need to grow and thrive. While it’s true that as air is compressed, much of the moisture present in the intake air will condense, enough moisture remains to allow micro-organisms to proliferate. …


Your compressor installation is a workhorse that requires regular service and maintenance to help it achieve maximum efficiency and longevity. This is where compressor monitoring and data gathering technologies come in, as these provide meaningful information on your system that can be visualized, tracked over extended time periods, and used to make insightful decisions regarding compressor performance.  …


A variable speed compressor is not for every application. VSD rotary screw compressors need to be ran in a location that is in need of 24/7 compressed air and has a changing demand on the amount of air needed. If your compressed air needs are constan... …


Compressed air purification equipment must have a very low pressure drop, long service life and be strong enough to withstand the most strenuous operating conditions. Protection from oil slugs or compressor air/oil separator failure is essential. …


Intelligent Connectivity System (ICONS) is the eyes into your compressed air system. Ditch the logbooks, the regular visits to the compressor room and dealing with surprises with your compressor. • Most maintenance organizations operate between 10% to 40% efficiency • Most spend more than 50% of time on emergency work • Reactive maintenance costs 3-5 times more than preventive maintenance. …


Compressed air is used in many different industries. From refrigerator manufacturers to toy makers, companies around the world depend on compressed air to produce products. It's so important that many consider it a utility as significant as electricity, water or natural gas. …


Compressed air is always contaminated. Contaminants include, • Liquid oil - oil aerosols - oil vapor, Dirt - microorganisms - pipescale, Trace gases: carbon monoxide, sulfur dioxide, nitrous oxide. Learn more about why you need to filter compressed air...  …


As part of a concerted effort worldwide to reduce energy consumption, CO2 emissions and the impact of industrial operations on the environment, regulatory authorities in many countries have introduced legislation to encourage the manufacture and use ... …


Air is always contaminated with solid particles such as dust, sand, soot, salt crystals and water as it leaves the compressor. An effective compressed air treatment system lowers the dew point of the air and takes out the elements that may harm equipment downstream of the compressor and dryer …


Dewpoint spikes immediately after desiccant switchover (line C) indicate that the desiccant was not sufficiently cooled before being brought on-line. Hot desiccant will not adsorb moisture well until it cools down, after which the dewpoint should dro... …


Don’t be alarmed if you find oil in your air compressor tank. Actually, all rotary screw compressors pass trace amounts of oil in the compressed air. The question is how much is the normal amount of oil in my compressor tank? …


As you know, compressed air filters protect your machine from dirt, dust, oil and water. These contaminants are extremely common in the areas you would find a compressed air system and will wear down your machine if not properly filtered out. …


Air compressor leaks can be a substantial source of wasted energy in any system, sometimes wasting 20-30% of a compressor's production. Worst of all, a poorly maintained compressor can have a leak rate expected to equal 20% of total compressed air... …


Choosing the right compressor is essential to your long-term satisfaction and maybe, to the profitability of your business. Many times compressors are based on a single factor alone, such as horsepower or tank size, which is only part of the story. …


In oil injected screw compressors, there is a thin layer of oil found between the rotors to create a seal and maintain proper efficiency as the compression occurs. The unfortunate side effect of this solution is that oil may carry over to the point of use in your air system. This can be mitigated by having correct filtration in place to remove the oil contaminants in your air. Additionally, many individuals may decide to opt for a completely oil-free solution, with the use of a scroll compressor or water injected screw compressor. …


Most businesses concentrate on the air compressor and consider the piping as a secondary concern. The piping system can make or break your business. Faulty, inefficient piping can cause pressure loss and lost power. Keeping a close eye on the overall layout, installations and maintenance of your air piping system will help keep your business running at its’ optimal efficiency. …


Our #1 Focus is Customer Service! Whether you have questions about which compressor is right for you, or if you’re ready to improve your operations and start saving on expenses. Ash Air has been around for over 40 years because we offer reliable and hardworking air compressors, vacuum pumps, and services as well as expert advice and support. …


An oil analysis can prevent problems later down the road. It's often been referred to as the blood test for your compressor. Just like a blood test can tell you about your health and early alerts to impending problems, an analysis can do the same for your compressor. …




Did you know that pressure drops and leaks are the two largest areas of energy loss on your air compressors? It’s easy to understand why a leaking pipe or fitting creates energy loss. Pressure drops are not quite as noticeable, since you cannot hear ... …


Whenever anything doesn't work properly, it's frustrating and we get it. If this is your first time experiencing troubles with your dryer, you're probably unsure where to even start. Getting your dryer repaired and back up and working is critical to ... …


Screw compressors are helpful for an enormous range of applications such as air filling, packaging, tools, HVAC control, and more! One possible drawback is the amount of electricity they use; air compressors can be a huge drain on energy if used ​ine... …



Most air compressors require constant oil lubrication to prevent friction on the pistons or screws and other moving parts. To make sure your air compressor is running efficiently, it is important to check your oil level regularly and to know how much... …


Have you heard of the term "Total Air Solutions"? A total air solution means everything that goes with the compressor for your business’s air system. 90% of companies require more than just an air compressor.  …


When speaking of air compressors, compressed air treatment is a process that dehumidifies and cleans air before entering the compressor. Most commonly, this process involves air filters and an air dryer. …


Air compressors are used in many different applications and provide essential compressed air to many businesses and individuals with different air needs. No matter what your CFM, PSI and HP requirements are, the electronic controller on your air compressor is the motherboard for keeping your unit running as efficiently as possible. It is your eyes into your machine. …


Air compressors are helpful for an enormous range of applications such as air filling, packaging, tools, HVAC control, and more! One possible drawback is the amount of electricity they use; air compressors can be a huge drain on energy if used ​inefficiently​. If you are running them too long, allowing leaks to exist, or using the wrong type of compressor, you are wasting ​energy and money​. This article will go over some of the biggest power-wasters and how to
stop/prevent them! …



In the following guide, we want to try to answer some of the questions you may have been asking yourself in regards to screw air compressors. If you do not find the answer you are looking for, please get in touch with us. …


Compressed air is a key utility supporting the food packaging and food processing industries. It is used in machines that fill products such as cakes, pies, and liquid products, as well as during the packaging and transportation of snacks, vegetables, beer, soda and other items.. Compressed air must be moisture and contaminant-free to ensure the protection of the food products processed in each facility.  …


Minimizing the risk of accidents in the workplace is a top priority in industry, and it is especially important when working with pneumatic power tools. Ensuring that all safety precautions have been taken to protect the health and wellbeing of operators is vital. With this in mind, here are seven simple steps to reduce the risk of accidents and improve operator safety …


Regardless of the type of compressor you have, vibration issues can be troubling for any business. The root of the vibration can stem from multiple sources, some internally and others externally. Understanding the cause of the vibration and how to resolve them will be critical in keeping your compressor in proper working order. …


Air compressors are essential to your business, but they can also become a safety hazard when used improperly. Reading your owner’s manual and following all proper safety precautions before use is vital in keeping your compressor in great, working condition. …


Corrosion in the pipeline is due to insufficient condensation drainage that occurs during compression. The resulting condensate, together with the compressed air, flow further into the compressed air line network and has a negative effect on the pipes. Find out more about how you can prevent corrosion here. …


FRLs – Filters, Regulators and Lubricators – guarantee the efficiency and durability of pneumatic tools. Including an FRL in your air system is vital to running an efficient air line set-up and key to achieving a good return on investment. Read more here! …


Check out this blog and video included to help you know what you should be looking for when you're thinking about purchasing a Chicago Pneumatic Rotary Screw Compressor for your shop or application. If you want to learn about what a screw compressor actually is, check out this article   …


There are 3 simple steps to make sure your air line installation is providing the right pressure and that your accessories selection is correct, so you can ultimately work productively. It does not take long and it is something you can easily do yourself using our self-diagnostic checklist.  …


Okay, okay, we're a bit excited. With the recent launch of our air tools in our online shop. Here's a 101 for you about what air tools you might need in your air compressor tool kit. Air tools are prevalent in automotive industries, woodworking, construction, metalwork and more. Did you know that there's pretty much an air-powered version nearly any power tool on the market? We want to share with you our 'Must have Air Tools'. …


When you are thinking about an air compressor, you might be have the image of the super popular piston or reciprocating compressor in your mind. The compressor that you see in home workshops, automotive garages pumping up tyres and assisting in spray painting cars. …


As a follow on to our Why You Should Not Use PVC Piping for Your Compressed Air System blog, we share with you what piping you shouldbe using to get the most out of your compressed air system. Here at Ash Air we have the perfect solution if you're wanting to match your great compressor with a fast, easy and reliable piping solution that supports the operational excellence of your whole compressed air system.  …


An air compressor is a big purchase for any business. It is visibly important to properly maintain the air compressor and filter elements to protect that investment. Air intake filters are installed in an air compressor to remove any dust or debris the compress may suck in. Dust will cause wear to the compressor element, valves, filters, compressor oil and any moving parts. …


So you have a vacuum pump installed and you rely on it for your business operations and performance? Here are some reasons why you should consider overhauling your vacuum pump! s with all machinery and compressed air equipment, regular maintenance can help ensure optimised safer performance of your vacuum pump. Learn more about benefits of restoring, rebuilding and repairing your vacuum pump. …


Air compressors are used every day, by many industries around the world. They are often considered the heart of a business, in that most companies will rely on their performance and efficiency to run their operations, to get work done effectively and safely. In your day to day, you've probably seen air compressors in use - whether at a build site powering construction equipment or in a mechanics workshop inflating tyres. …


A scroll air compressor, or spiral compressor, compresses air by drawing it it, trapping it, reducing the volume and discharging it at the outlet port. The scroll compressor that you see today, such as SpiralAIR, have been the result of modernised advancements in manufacturing technology, even thought the concept of a scroll compressor has been around for over 100 years.The scroll compressor is oil-free orbiting, or positive displacement compressor. The compressor has a stator spiral fixed in a housing, and a motor driven eccentric orbiting spiral.  …


Air compressors come in many types, rotary screw, piston, scroll, reciprocating, some are oil-free and other air compressors require oil lubrication. Like many businesses, an efficient air compressor is at the heart of their operations. So, which type of compressor should you choose? What makes a compressor, like a rotary screw, unique? Here are some clear cut benefits of equipping your business with a rotary screw compressor.   …


In the world of compressors, there are often significant and unutilized energy-saving possibilities including energy recovery, pressure reduction, leakage reduction and optimization of operations through correct choice of a control and regulation system as well as the choice of compressor size.We are going to take a look at some of the opportunities for minimizing the compressor’s operating costs.  …


Liquid water in compressed-air systems can lead to rusted equipment and unresponsive controls. Anyone who uses compressed air will, at some point, find liquid water in the air distribution system. This can be anything from a nuisance to a serious problem, depending on the application. If water might corrode equipment or introduce bacteria, removing it is critical.  …


Liquid water in compressed-air systems can lead to rusted equipment and unresponsive controls. Anyone who uses compressed air will, at some point, find liquid water in the air distribution system. This can be anything from a nuisance to a serious problem, depending on the application. If water might corrode equipment or introduce bacteria, removing it is critical.  …


Whenever most people think about a compressor, they probably have a piston compressor in mind. You might already know there are two basic principles of air compression. One of those is the principle of displacement compression. There are a lot of compressor types that classify as a displacement compressor. The piston compressor is one of them, oil-lubricated or oil-free.  …


Once you have the size and type of compressor figured out, one last question remains, should I go with an oil lubricated or oil-free air compressor. To not overcomplicate the answer, your choice should be based on the application and process that the compressed air will be utilized in. …


Like all compressor types, rotary screw models do require periodic maintenance. Thanks to the simplicity of the internal components, maintenance is relatively easy on most rotary air compressors. As long as you stick to a rotary screw compressor maintenance schedule, you will likely be rewarded with many, many years of optimal productivity from your machine.  …


Did you know, the biggest part of the air we breathe is nitrogen? Everyone needs oxygen to survive, however air is made up of 78% nitrogen, only 21% oxygen and tiny amounts of other gases. Although, the human body does not use this nitrogen, it is very helpful in various industrial applications. There is an unlimited source of nitrogen readily available, allowing you to achieve needed purity at a fraction of your current annual nitrogen cost.  …


If you notice that your compressor is getting hot and bothered, there may be heating issues affecting your air compressors performance. Did you know that an overheating compressor is top of the pops for being the most common cause of compressor failure.  …


A rotary-screw compressor is an air compressor that uses a rotary-type positive-displacement mechanism, typically used replace piston compressors where large volumes of high-pressure air are needed, either for large industrial applications or to operate high-power air tools.  …


Have a look around and what do you see? What are you thinking about? Your next holiday to Queenstown maybe? You might go snowboarding with the kids or have some alone time at the Day Spa. Whatever holiday you choose, compressed air is involved in some way, without you even realising it!   …

Show More