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Air Compressor Solutions


We have been providing businesses like yours with simple and innovative solutions for nearly 30 years. 

Some of the solutions we provide include:

  • Upgrading an old machine running on logic controls to a modern controllers
  • Decreasing energy costs
  • Eliminating production bottlenecks
  • Improving safety for employees by automating a process
  • Meeting stringent air quality requirements specific to industry
  • Increasing production capacity.

We can also advise you on how to mitigate the effects of condensate.

Total Air Care Solutions for clean and dry air

 

Whatever the weather, we can provide solutions to the challenges of condensate. Frosty weather keeps our service technicians busy during winter as condensate causes callouts.  Summer’s high temperatures can also cause condensate concerns.

There are multiple ways of mitigating the effect of wintry weather on your compressed air supply. This includes using air dryers, preventative maintenance through our AirCare✓ system and having a strategic location for your compressor, especially those with refrigeration systems. Phone or email  Compressed Air Controls for information on 06 3552993 or email us today. 

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Weather can cause condensate concerns

Condensate, which is formed when air is compressed and then cooled, is a mix of mostly water and a little oil. It can cause compressors to break down all year round. In the winter, if temperatures fall low enough, this condensate will freeze, blocking pipes or voids and can cause damage to the compressor, filters, dryers and the downstream equipment.

If the compressor is not serviced proactively and the oil is aged or of poor quality, the oil may thicken when it is cold and this may prevent the compressor from turning easily enough. This may lead to the electrical system tripping since the electrical demand is too high.

Another cause of concern with condensate and a compressor that is not serviced regularly is that it is possible that the oil will contain a high level of water. If the temperature falls too far this water can freeze in the oil, causing issues for the compressor at start up or causing damage to the compressor internals.

There are multiple ways of mitigating the effect of wintry weather on your compressed air supply. This includes using air dryers, preventative maintenance through our AirCare system and having a strategic location for your compressor, especially those with refrigeration systems.

Dryers can prevent problems

ELGi has refrigerant and desiccant Airmate air drying systems. These will reduce wear and tear on your compressors by removing contaminants like condensate and dust. This resulting clean, dry air will increase the reliability of your compressed air systems and maximise energy savings, while being environmentally friendly. The refrigerant system removes water by cooling the compressed-air temperature and causing condensation. An internal moisture separator collects the water and sends it to a drain. 

The desiccant systems works by absorbing moisture from the air stream onto a desiccant material in a reversible process. They produce low dew points, so they are a good choice in subfreezing conditions or when processes require extremely dry air. This desiccant material is housed in two adjacent tanks, called the drying tower and regenerating tower. Moisture-laden compressed air flows into the drying tower, where it passes over and binds to the porous desiccant. Extremely dry air exits the dryer. The absorption process also generates heat, which is then used to remove water from the desiccant. The already dried air that has moved to the regenerating tower expands and pulls water off the desiccant. Moist air is then discharged from the system. The dryers take turns at drying and regenerating operations at regular intervals, so one tower always dries the incoming air.

 

Our AirCare✓ system can help too

Our AirCare✓ system predicts when your compressors need some attention and therefore can avoid the cost- not just of our labour but lower production through downtime- and stress of breakdowns.

Location, location, location

Any business that is building new should think about the strategic location of their compressor. If it can’t be housed in the main building, then putting it in its own well-ventilated shed can help protect it from chilly weather.  

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Here are a few things that you can do to help your air compressor cope in summer’s heat:

  • Oil/Air Cooler: Check the cooler pack is free from dust build up. Some models will have two coolers (one for the compressor and one for the integrated compressor air dryer).

  • Drains: Drain the condensate from the filters and receivers. 

  • Ventilation: Check that the compressor is well ventilated and that none of the vents are blocked.

  • Oil levels: Check that there is enough oil. Oil is used to cool compressors, so if the oil is low, it has to work much harder to cool the compressor.

A regular service will help to ensure your compressor is in tip top condition and working as efficiently as possible in these increasing high temperatures. Contact us on 0508 763 862 to book this in today.

The importance of condensate drainage

Higher humidity in the summer causes more condensate in the compressed air system which has to be drained. Investing in drains that are right for your application demands and having them installed correctly will ensure your compressed air system will be free from the damaging effects of liquid, oil and carbon.  

Talk to us about advice on any of this.

You can read about some of the solutions we have provided in our case studies here and read more about ELGi's AirMate Accessories here