A Technical Guide to Choosing Air Treatment Systems for Industrial Applications

Air quality directly impacts the performance and lifespan of downstream equipment. 

Contaminants such as moisture, oil, and particulates pose serious risks to product quality, operational uptime, and regulatory compliance. The International Organization for Standardization (ISO) outlines standards under ISO 8573:2010 to classify air purity, which serves as a baseline for determining system requirements.

This guide is intended for engineers, maintenance managers, business owners, and procurement professionals responsible for specifying and maintaining compressed air systems. It outlines the air purity requirements for various industries, air treatment equipment options, and the performance characteristics to consider during selection.

The Impact of Compressed Air Contaminants

Compressed air is often considered a ‘fourth utility,’ but you should also treat it as a process medium. Untreated compressed air can contain over a million dirt particles per cubic meter, along with oil aerosols, water vapor, and condensed moisture.

Major Contaminants:

1. Water Vapor and Condensate: Ambient air holds moisture. Moisture in compressors leads to corrosion, equipment damage, and reduced air quality throughout the system. According to the Compressed Air and Gas Institute (CAGI), a rule of thumb is that for every increase of 20ºF in the temperature of air, its potential for holding moisture doubles.
2. Oil (Aerosols, Vapor, and Liquid): Oil originating from lubricated compressors or ambient air fouls actuators and sensors and contaminates end products.
3. Particulates: Dust, dirt, rust, pipe scale, and metal shavings introduced to the compressed air from the ambient air or internal corrosion.
4. Microorganisms: Bacteria, fungi, and mold thrive in moist conditions.
5. Other Gases and Vapors: Carbon monoxide, carbon dioxide, hydrocarbons, or airborne chemicals from the surrounding environment can mix with and contaminate compressed air.

Failure to remove contaminants can result in unplanned downtime, premature equipment failure, compromised product integrity, and safety hazards.

Air Purity Level Classifications

ISO 8573-1:2010 defines compressed air purity classes for solid particulates, water, and oil. Each class specifies acceptable levels of contaminants in terms of microns, mg/m^3, or vapor pressure dew point. It does not define purity classes for gases or microbiological contaminants.

Selecting air treatment equipment starts with defining the required class based on the application. The following industries typically fall under each class based on air quality needs but some exceptions do apply. 

Operators in the Central, Midwestern, and Southern Ohio Markets, as well as Northern Kentucky Market can contact one of our experts for a professional review of your application and air treatment recommendations.

Class 1 – Ultra-Clean

Used in sterile or highly sensitive environments.

Industries: 

• Pharmaceutical manufacturing (tablet coating)
• Semiconductor and microelectronics (clean rooms)
• Food & beverage filling (aseptic, sterile environments)
• Hospitals (surgical air, respiratory use)

Class 2 – Very Clean

High-purity air for processes that demand cleanliness but not sterility.

Industries: 

• Dairy processing (non-aseptic)
• Brewery and distillery (bottling, carbonation)
• Cosmetic production
• High-end automotive painting

Class 3 – Clean

Clean air for precision manufacturing without strict sterility.

Industries: 

Food packaging (dry goods, non-aseptic)

• Beverage canning
• General electronics assembly
• CNC machining with pneumatic tools
• Plastic injection molding

Class 4 – Standard Industrial

General-purpose compressed air with basic filtration.

Industries: 

• Automotive assembly
• Textile manufacturing
• Printing (offset, flexo)
• General manufacturing lines

Class 5 – Moderate Quality

Moderate air quality for processes where some contamination is acceptable.

Industries: 

• Tire production
• Foundries
• Cement plants
• General workshops and garages

Class 6 – Low Sensitivity

Minimal filtration for rugged or less-sensitive environments.

Industries: 

• Quarry operations
• Large construction sites
• Steel and iron production
• Heavy equipment maintenance shops

Class 7 – High Tolerance

For rough applications with high moisture or particle tolerance.

Industries: 

• Mining operations
• Shipbuilding and dry docks
• Power plants (non-precision pneumatics)
• Bulk transport depots (pneumatic conveyance)

Class 8 – Minimal Requirements

Compressed air used in non-sensitive environments.

Industries: 

• Wastewater treatment plants
• Agricultural equipment (non-food-related)
• Pulp and paper mills
• Concrete batching

Class 9 – Untreated Use

Unfiltered air for heavy-duty, rugged tools or non-contact use.

Industries: 

• Sandblasting
• Pneumatic excavation
• Demolition tools
• Remote pipeline venting
• Heavy-duty mining rigs

Types of Air Treatment Equipment

1. Dryers

Dryers reduce and remove moisture and prevent condensation. The primary types we offer include:

Refrigerated Dryers

Working Principle: Refrigerated dryers cool compressed air to condense and separate moisture before reheating the air to prevent condensation in downstream lines.

Dew Point: Typically +35°F to +50°F

Applications: Ideal for general-purpose industrial use needing moderate moisture removal

Air Handling Equipment Advantages: 

• CAGI-verified performance
• Cycling and Non-Cycling configurations
• High-inlet temperature models 
• High-pressure models available
• Air and water-cooled options
• 15-12,000 CFM packages

Limitation: Not suitable for applications requiring very low dew points or operating in sub-freezing environments

Desiccant Dryers

Working Principle: Desiccant dryers absorb moisture from the air using desiccant material, such as silica gel or activated alumina, to adsorb water as the air flows through the system.

Dew Point: -40°F to -100°F

Applications: Ideal for applications that require strict air purity standards

Air Handling Equipment Advantages: 

• Delivers ultra-dry air, suitable for sensitive equipment
• 20-20,000 CFM units
• Heatless, externally heated, blower purge, and heat of compression options
• Meets Safe Quality Food (SQF) and Global Food Safety Initiative (GFSI) standards for direct food contact

Membrane Dryers 

Working Principle: Membrane dryers remove moisture from compressed air by allowing water vapor to pass through semi-permeable membrane fibers while retaining the dry air for use downstream.

Dew Point: -40°F to +40°F

Applications: Ideal for applications with low to moderate flow rates 

Air Handling Equipment Advantages: 

• Point-of-use drying
• Consistent dew point suppression without electricity
• Operating pressure up to 200 psig

2. Filtration Systems

Compressed air filtration extends the life of your equipment by removing oil carryover, moisture, and solid particles. Air Handling Equipment offers a full range of filtration systems, including particulate filters, coalescing filters, and mist eliminators, to match your system’s demands.

Air Handling Equipment Advantages:

• Units available with flow rates from 20 to 21,250 CFM
• Pressure ratings ranging from 100 to 6,000 psi
• Configurable solutions tailored to your air system requirements
• Food-grade filtration available, including sterile options that align with SQF and GFSI standards

3. Condensate Management Systems

Compressed air systems naturally produce condensate that must be discharged to avoid contamination and corrosion.

Drains

Used with filtration systems and oil-water separators, drains help eliminate unwanted moisture, chemicals, and water from the air in your compressed air system. We offer efficient drain solutions to support reliable operation and reduce energy consumption.

Air Handling Equipment Advantages:

• Float, timed, and zero-loss drain options
• Manual, electric, and pneumatic configurations
• Flexible designs that fit a variety of systems and compact spaces

Oil-Water Condensate Separators

According to Gardner Denver, a single 100 HP air compressor can carry over 15 gallons of lubricant annually. 

Oil-water condensate separators separate oil, water, lubricant, and particulates produced during air compression. They help manage condensate safely and meet United States Environmental Protection Agency (EPA) regulations for proper disposal, local discharge regulations, and environmental compliance. We supply oil-water condensate separators from industry-leading brands for reliable performance across various applications.

Air Handling Equipment Advantages:

• Compatible with diester, PAO, glycol, hydraulic, food-grade, and mineral-based lubricants
• Available in collection capacities from 0.5 to 60 gallons
• Suitable for systems ranging from 30 to 10,000 CFM
• Options for cartridge replacement and low-maintenance
• Proprietary Tank Connections

Factors to Consider When Choosing an Air Treatment System

Air Handling Equipment partners with our customers to properly size, specify, and configure air treatment systems that meet their operational and regulatory requirements. Our team considers application needs, system demands, and industry standards to deliver effective and efficient solutions.

While we’ll handle the detailed calculations and system design, the list below offers a starting point for what to consider during the early stages of your system planning and research.

Required Air Quality Standards

Determine the ISO 8573-1:2010 purity classes required for particulate, water, and oil based on your end-use applications.

Application Sensitivity

Assess whether compressed air will contact products, instruments, or critical processes that require specific air purity levels.

Compressor Configuration

Consider whether the compressed air system uses an oil-lubricated or oil-free compressor.

Flow Rate (CFM) and Demand Profile

Evaluate current and peak compressed air demands to ensure accurate sizing of dryers, filters, and ancillary components.

Operating Pressure (PSIG)

Understand system pressure requirements, which affect the performance and selection of treatment equipment.

Ambient and Environmental Conditions

Factor in inlet air temperature, relative humidity, and airborne contaminants that may influence system performance and maintenance intervals.

Distribution System Layout

Consider the length, configuration, and materials of the piping system to identify potential pressure drop points and contaminant introduction.

Energy Efficiency Objectives

Review options that align with energy reduction goals, including low-pressure-drop filters and energy-efficient dryer technologies.

Maintenance and Service Access

Evaluate long-term maintenance needs, replacement part availability, and ease of service access for installed components.

Regulatory and Industry Compliance

Ensure the system meets applicable standards such as FSMA, FDA, GMP, ISO, or industry-specific requirements.

Buy, Rent, or Lease Compressors Integrated with Air Treatment Systems

Protect your bottom line and preserve capital while investing in clean, reliable compressed air. Compressed air systems are an investment, so we offer flexible options to buy, rent, or finance compressors integrated with air treatment systems.

Customers have come to us needing permanent installations, temporary setups during peak production, and even trial systems to evaluate performance before a larger investment. Our team works with you one-on-one to recommend a tailored system and provide full support throughout the lifecycle of your equipment.

Get the system you need on your terms without compromising your budget. 

Prevent Costly Damage to End-Use Equipment and Products

Reliable air treatment maintains consistent performance and protects your equipment. 

We partner with leading manufacturers like Gardner Denver, ZEKS, and NANO to deliver air treatment equipment that performs reliably under pressure. Integrating proven solutions into your compressed air system reduces the likelihood of unscheduled downtime and improves process consistency.

We design compressed air systems built to meet technical demands and support them with responsive service and trusted equipment partners. We hope this guide helps you make informed decisions as you evaluate options and plan your system. Our team is available to clarify technical details, compare equipment, and recommend solutions that meet your goals. 

Connect with us to confidently move forward and build a system that supports long-term air purity and performance.