Upgrading Compressed Air: How-To Guide for Building a Winning System

At Air Handling Equipment, our mission statement leads our focus into all customer opportunities. We help our customers reach their goals by eliminating compressed air system downtime and inefficiencies. To do this, we lead with five areas of consideration to build a winning compressed air system:

Compressed Air Supply and Demand
Compressed Air Quality
Compressed Air Storage
Compressed Air Distribution
Compressed Air Energy Efficiency

Compressed Air Supply and Demand

Whether you are designing a new compressed air system or modifying your current one, it is important to plan for a compressed air system that will optimally supply air to meet the new demand. There are normally two economical ways to “right-size” a new compressed air system: 1) Install a flow meter to monitor air flow and 2) Install data logger(s) to existing compressors to record and report current activity.

Flow meters provide a direct measurement. Instead of attempting to calculate air flow based on assumed relationships between system pressure and compressor’s electrical consumption, you can measure the air flow at various points in your facility. Which is why we consider flow metering a critical component to air compressor sizing to avoid oversizing compressors, reducing performance and increase power usage (kW).

Data logging is the practice of measuring system performance by attaching data logger equipment over a period of time while the compressed air equipment is in operation. Unlike flow meters, data logging allows us to see how the system responds to real-time events and conditions over time. This enables us to find trends and correlate system performance to possible causes and drivers. Data loggers can measure pressure, temperature, moisture dew point, flow, amperage, and voltage. Knowledge is power and this knowledge can optimize your compressed air system.

Compressed Air Quality

Moisture can be detrimental to your compressed air system productivity. Air Handling Equipment has utilized dew point monitoring to prevent production downtime and product rejection, saving our customers money. Customers may think they need an additional air treatment system because their tools are seeing accelerated wear and damage. However, being proactive with preventative maintenance plans can elongate the lifespan of your existing compressed air system. If you are installing a new line that requires additional levels of air quality, we will look at point of use systems, rather than an entire system to economically and efficiently support your new compressed air quality demand.

Compressed Air Storage

Storage tanks are an integral part of the efficiency of your compressed air system. A properly sized tank will help control any demand spikes, providing a buffer to your compressed air system. This prevents your compressor from cycling too often, potentially accelerating the wear and tear on your internal components of the compressed air system. In addition to a properly sized storage tank, a flow controller can provide that constant line pressure and safeguard the compressed air storage for changes in air demand downstream.

Compressed Air Distribution

Another important consideration in compressed air system design is to rule out any leakage and artificial demand in the current system. This is why Air Handling Equipment has partnered with Sonotec to utilize state of the art technology in ultrasonic leak detection. Our Technical Solutions Group will map your facility for any leak areas that could be inflating your air demand. Additionally, our team will review your existing compressed air pipe system for optimal design. From our analysis, we may recommend:

Close loop the entire compressed air pipe system or certain production areas to create an even distribution of air flow
Repair air leaks
Install a flow controller to maintain stable system pressure and reduce air loss through leaks

Compressed Air Energy Efficiency

Unfortunately, compressed air is an expensive utility to produce. Energy costs can account for over 75% of your air compressor costs after installation. When upgrading your compressed air system, consider these factors in energy efficiency:

● Utilization
● Electrical Power
● Capital Budget vs. Operating Budget

Variable speed compressors can be smart solutions in maximizing efficiency, while lowering the total cost of ownership. Upfront purchasing cost can appear to be a disadvantage; however, when understanding a typical compressor operates at 70% load, energy costs can be reduced significantly over the lifespan of your equipment, creating a cost savings and a short return on investment (ROI). Always be mindful of costs associated after the sale vs. the upfront capital cost before making your final decision.

Beyond these 5 integral areas to consider when building a winning compressed air system, Air Handling Equipment is considerate of other factors, such as:

1. Time
2. Budget
3. Warranty
4. Maintenance
5. Installation
6. Unknowns

1. Time

There are situations when time to implement is short. Air Handling Equipment is prepared with a large fleet of stock, used, and rental equipment. Depending on your timeline, we can fulfill a permanent or temporary need when working through building your new compressed air system.

2. Budget

Air Handling Equipment has two options to assist with capital budget constraints. The first is to consider purchasing from our vast selection of used equipment. Our team always makes sure to have our used equipment in good standing before delivering to our customers. Call or contact us today for an updated list of our used equipment inventory. The second option is financing through Gardner Denver. As an authorized distributor of Gardner Denver, Air Handling Equipment makes equipment leasing easy. Check out the Financing page for more details.

3. Warranty

Air Handling Equipment utilizes the best warranties in the industry with our partnered brands. Warranty can provide peace of mind for you after installation of your new compressed air system. With a comprehensive warranty plan in place, you receive optimal care for your compressed air equipment and minimize the risk against unplanned downtime and interruptions to your production. Call or contact us today to ask about our warranty programs or check out our Brochures page to review our Gardner Denver Warranty Programs for more details.

4. Maintenance

The #1 way to lower your total cost of ownership is by planning ahead with maintenance. Proper maintenance after installation is vital for the reliability, efficiency, and overall cost of your compressed air system. Air Handling Equipment will take care of all your service and preventive maintenance needs. Our dedicated team of technicians, account managers, and service and parts personnel will all work cohesively to meet your production demands. Ask us today about our UPTIME performance and how you can benefit from customized plans.

5. Installation

Air Handling Equipment is fully equipped with an Installation team capable of providing turnkey solutions for plant air and fluid distribution. Services include:

● New compressed air system start-up
● Replacing current pipe system
● New/added pipe system project
● Layout consultation

Building our own Installation Team in-house at Air Handling Equipment has passed on significant savings to our customers. With availability of product and technicians specific to install needs, we can keep your schedule on time and budget. Contact us today to ask about installation needs.

6. Unknowns

Sometimes we don’t have all the information in front of us. That is ok. Our team of experts have almost 50 years of experience in the industry. We can adapt to the knowns and unknowns with our experience to our existing customer base, especially those within your industry. Our team has seen it all to confidently provide compressed air system solutions to our customers in Ohio. Our mission is to help our customer’s reach their goals by eliminating compressed air system downtime and inefficiencies. You can trust this will be our every effort!

Have more questions about building or upgrading your compressed air system? Fill out our contact form or contact one of our Ohio locations in Sidney, Cincinnati, or Columbus!