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Moisture, lubricants and particulates can reduce the efficiency of your compressed air system.

For sensitive industries like pharma and food manufacturing, even a small trace of contaminant can lead to wasted product, unnecessary downtime and business liability.

That's why these AirMate accessories are essential.

AirMate filters are designed to remove particulates from the compressed air system and remove excess lubricant especially in sensitive industries like pharma and food.

Aftercoolers cool the hot compressed air before it heads towards the end application. Once the air is cooled, the water is removed, leaving the compressed air close to the surrounding temperature. This cooler compressed air will therefore not cause any condensation to form in the pipes or any process degeneration.

Dryers are essential because compressed air contains water, dirt, bacteria and even degraded lubricating oil. All these impurities mix together to form an abrasive sludge. This sludge is often acidic and accelerates wear and tear of tools, pneumatic machinery, block valves and orifices. This results in costly air leaks and high maintenance. It also corrodes pipes and can bring the production process to a standstill. Only compressed air that is totally clean and dry will ensure the reliable working of the compressed air systems and maximum savings. 

ELGi have two types of dryers:

  • The favoured method of drying the compressed air is through refrigeration dryers because they have:
    • High-efficiency thermal mass technology
    • Microprocessor-based digital dew point controller
    • 100% modulating cycle controller
    • Electronic auto condensate drain
    • Ozone friendly refrigerant
    • A compact design
    • Low-pressure drops
  • Desiccant air dryers- read more about how these are the better option for industries like dentistry than refrigerated compressed air dryers, as they will create a much lower pressure dewpoint so the chance of bacteria growth is very low.

Drain valves- read more about ELGi's“Zero loss advantage”.

Air receivers- click here to read more about why you should invest in an ELGi Air Receiver.

Oil/water separators: When the air is compressed through compressor, it results in condensate along with compressed air. Condensate – A mix of water, oil & dust particles. If not treated properly and releasing it to the environment, this condensate can make detrimental effects of environment. Regulatory bodies for effluent treatment recommend that these condensate should be cleansed before releasing it to the sewage disposal. ELGi EOS series is specifically designed to maintain less than 10ppm of oil in the condensate before allowing the fluid to pass on to the environment. Thanks to the multi-Level separation process with both super-efficient fiber adsorbent and Activated carbon, which ensures the contaminant levels are kept well within the statutory requirements.

Variable Frequency Drives (VFD): The Conserve VFD is a type of adjustable-speed drive which controls the motor speed by varying the frequency applied to it.

What does adjusting the speed do?

The motor speed is directly proportional to the frequency and thus changes in frequency impact the motor speed and the amount of power consumed. 

The VFD can transform air compressors that have traditionally been known as power guzzlers into energy-efficient equipment.

How much energy can be saved?

Once it is fitted with a VFD, the energy cost of an average compressor comes down by 18 percent. 

This calculation is based on the assumption that it is a compressor with a running life of 15 years, runs 24 hours a day and has a load-unload cycle of 70:30. 

Examples of cost savings with VFD

An India-based automobile company recorded around 40 percent savings in its power costs after fixing VFDs in its ELGi EG 37-7.5 compressor. 

The company uses compressed air for applications such as castings for sandblasting, painting and dust removal. 

The company received the ROI in just six months. 

Since the heat generated in the compressor reduces with the VFD, the company can also expect better longevity of the compressor’s parts like the intake valve and air-oil separator, and extended oil life.

Three ways to save energy

25 percent energy savings due to the elimination of the unload cycle.

In general, compressors work in the load-unload mode. 

When there is demand, compressor loads and allows the pressure to rise, and unloads once it reaches the unload pressure set point. 

The compressor cannot be turned off since the motors are not designed to frequent switching on and off. 

During the unload cycle, the intake valve closes and there is no air flow, but the motor continues to run at the rated speed. 

The compressor consumes 25-30 percent of power. 

With VFD, there is no unload cycle, and air continues to be produced at the required pressure.

7 percent energy saving due to reduction in operating pressure.

If an application requires an operating pressure of 6 bar, the fixed speed machine operates on load-unload set points which are 6 and 7 bar, respectively. 

To compress an extra 1 bar, approximately 7 percent of additional energy is spent, which is a waste.

In a VFD-powered compressor, the pressure is maintained constantly throughout and this loss is eliminated.

3 percent energy saving due to leakage and pressure drop reduction.

Air leakages and pressure drops are inevitable in any compressed air system.

For every 1 bar increase in compressed air pressure, there is a corresponding 3 percent higher rate of leakage and pressure drop in the compressed air circuit, which demands extra power. 

Since a fixed speed machine requires 1 bar extra over the desired pressure, it is bound to lose energy on this account. 

In VFD-powered compressors, the pressure is maintained constant throughout the cycle and leakage losses due to increase in pressure are eliminated.

VFD compressors are highly effective ways to save energy during a compressor application.

If the requirement is 900 cfm, the base load will be shared by load-unload compressor of 400 cfm and the trim load will be shared by the 500 cfm VFD compressor.


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