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Nashville: (615) 256-0112
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Common Questions About Industrial Air Compressors
John Bouchard & Sons Co. is the Mid-South’s most trusted source of compressed air solutions. We help industrial and commercial customers source and maintain the quality equipment they need. Since there are many types of air compressors suitable for industrial purposes, identifying the right product can be a challenge. You can get started by reviewing the most common questions asked about industrial air compressors.
Whether you’re purchasing an air compressor for the first time or upgrading your current system, there are many factors to consider so that your project is a success. Browse our most frequently asked questions below, and reach out to us if you have any further inquiries. Our product experts would be happy to address your questions.
What Is an Industrial Air Compressor?
Industrial and manufacturing environments require robust compressed air systems. An industrial air compressor is a machine that delivers concentrated streams of pressurized gas to a system or piece of equipment. These electric-motor-driven machines produce compressed air, which is used for a variety of tasks, including:
- Powering air tools, paint sprayers, or abrasive blast equipment
- Driving equipment such as conveyor belts and impact equipment
- Injection molding, filling tires, or dust collector and filter cleaning
- Supplying shop or instrument air
What Are the Common Types of Industrial Air Compressors?
The three main types of air compressors are:
- Rotary screw air compressors. These compact yet powerful compressors feature two rotors that force air through a casing where it becomes increasingly pressurized. Rotary screw air compressors have a smoother, more consistent output than reciprocating models and come in oil-lubricated and oil-free varieties.
- Reciprocating air compressors. Also known as piston compressors or cylinder compressors, these tools work by creating a vacuum then compressing air and forcing it into a storage tank. The simple technology involved in this type of compressor makes it an affordable option, which is best for intermittent air demand (usage).
- Centrifugal air compressors. This type of air compressor features high-speed, rotating blades that create highly pressurized air. It is powerful enough for continuous use in large-scale applications, like natural gas and oil pipelines.
What Are the Best or Most Popular Brands of Industrial Air Compressors?
There are many industrial air compressor manufacturers to choose from, each offering unique features and advantages. While our team can help you find the ideal product for your needs, some of the most well-known brands you may want to explore include Gardner Denver, Atlas Copco, Sullair, Ingersoll-Rand, Quincy, Kaeser and Boge.
Which Compressor Is Best for Industrial Use?
While air compressor uses vary depending on the needs of each application, rotary screw air compressors are a popular choice due to their efficiency. These compressors consume less oil and conserve more energy than reciprocating compressors and are designed for all-day operation. They are ideal for duty cycles over 60% and run much more smoothly and quietly than reciprocating compressors.
What Size Industrial Air Compressor Do I Need?
Air compressors must not be too large or too small for their working environment. Determining the correct size is important for keeping your operations running efficiently and preventing unplanned downtime. It’s important to note that larger compressors aren’t necessarily more powerful than smaller models.
To get started determining what size you’ll need, consider the following factors:
- Air pressure. Air pressure is measured in pounds per square inch (PSI) and refers to how much air a compressor can deliver. The higher a compressor’s PSI is, the more air volume it can produce. Check all the tools and machinery you’ll be using with your air compressor and see what minimum pressure they require.
- Air delivery. Also known as volume flow rate, a compressor’s air delivery is expressed in cubic feet per minute (CFM) and represents how much air it can pump in one minute. The more demanding your needs are, the higher the CFM you’ll require.
- Power. Review both horsepower and power supply options for your air compressor. Horsepower refers to how much power your compressor’s motor offers, while power supply options include diesel, electric, and hydraulic. Each type of power supply has its own benefits. Electric options are most common due to low-maintenance and have affordable operating costs, while hydraulic compressors are typically easy to integrate with an existing power source. Diesel-powered air compressors have the benefit of motility and are often used in a construction setting where electrical power sources are scarce.
- Tank size. If you’ll be using your compressor continuously, you’ll need a larger tank that can store enough air to keep up with high demand. For intermittent use, a small tank is often sufficient.
- Duty cycle. Expressed as a percentage, duty cycle refers to how frequently a compressor can run before it must pressurize more air. For example, a 50% duty cycle indicates that after one minute of operation, two minutes are required to cycle in new air.
- Configuration and air capacity. Your operating needs will determine which configuration and air capacity are best. For example, rotary screw compressors feature high capacities and are designed for continuous operation. Single-stage and two-stage reciprocating compressors, on the other hand, have lower capacities, making them better suited for automotive repair facilities and other intermittent-use applications.
Most often, the best first step towards answering these questions is to conduct an Air Audit in order to profile the current dynamics of your facility’s air usage.
Which Type of Air Compressor Lasts the Longest?
Industrial air compressor lifespan varies greatly according to type and usage. Operating your air compressor in high-humidity areas or environments with extreme temperatures can reduce its lifespan. However, with proper maintenance, average life expectancy ranges from 5 to 20 years:
- Reciprocating air compressors: 50,000 hours (6 years)
- Rotary screw air compressors: 100,000+ hours (10+ years)
- Oil-free rotary screw compressors: 70,000 hours (8 years)
- Centrifugal air compressors: 250,000+ hours (28+ years)
Within these lifespans, a rebuild or overhaul of your compressor’s air-end may be required.
What Factors Affect Air Compressors Life Expectancy?
In addition to the temperature and humidity of your operating environment, several other factors impact air compressor life expectancy:
- Quality of materials and manufacturing. Industrial air compressors from trusted brands are made with quality materials and tested to ensure decades of reliable use. A poorly constructed compressor, on the other hand, may require frequent repairs or replacement.
- Frequency and intensity of use. Choosing an air compressor designed for your intended use is the best way to maximize its lifespan. For example, only certain types are capable of operating continuously.
- Maintenance and upkeep. Regular preventative maintenance tasks like oil changes, cleaning air filters, and checking belts and hoses prevent premature wear and keep your equipment operating at its best for as long as possible.
How Many CFM Is a Good Air Compressor?
Most air compressors that power tools offer anywhere from 10 to 110 CFM. To determine what’s right for you, find the CFM requirements for the most demanding tool. If you use multiple tools simultaneously, add their individual CFMs together and then multiply the result by 1.5. This will ensure your air output needs are met, even amid brief surges.
For more complex air usage, it may be best to consult an expert when determining the CFM demands of your operation.
Is a Bigger Tank Better for Air Compressors?
Tank size has a significant impact on how your air compressor functions. In most industrial applications, a larger air tank can reduce wear and tear on your system and improve its longevity. Advantages of a large tank include:
- Consistent pressure. Compressors pause when tank pressure reaches a certain maximum threshold. Larger tanks help achieve longer run times without pressure fluctuations or pulsating.
- Greater compressed air storage. Hold higher volumes of air for your production needs.
- Energy efficiency. Smaller tanks require more frequent power-ups, raising utility prices.
- Longevity. If your tank is too small, your system will have to work harder to provide the air you need. With a larger tank, your system will experience less wear and tear, reducing long-term maintenance costs.
Air Compressors at John Bouchard & Sons Co.
Due to the demanding nature of industrial work, choosing the right type of air compressor requires careful consideration. John Bouchard & Sons Co. offers over a century of expertise to guarantee you find the best option. We can even install an electric rental compressor to keep your operations running smoothly while we service or install your new machines.
Learn more about our Compressed Air capabilities here.
To get started with your ideal industrial air compressor solution, contact us today.
Do you have a project in mind? Contact us today for over 100 years worth of experience and integrity.