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How we mitigate the effects of condensate:

Condensate is a year-round challenge as both frost and high temperatures can cause damage to a compressor, but we can help prevent this.


There are multiple ways of mitigating condensate, this includes:

  • using air dryers
  • preventative maintenance through our AirCare✓ system
  • 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. 


What is condensate?

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.

Summer's high temperatures also create condensate in compressors, which can cause damage then too.



Dryers and 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.

How they work

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 system 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.

Not only can ELGi provide drains to remove the moisture, but their drains also have a zero loss advantage over other brands. Read more here.


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.  

What you can do to help your air compressor cope:

  • 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.

  • Be proactive: sign up for AirCare and we will keep an eye on your oil levels. 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.

A regular service will help to ensure your compressor is in tip-top condition and working as efficiently as possible.

Contact us on 0508 763 862 to book this in today.

Read more:

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