To Repair or To Replace?
To repair or to replace? That is the question
whether tis nobler in the shop to suffer
the slings and arrows of outrageous repair fortunes,
or to take arms against a sea of machinery troubles,
and by opposing these forces, buy new?
The decision to repair or replace your broken air compressor may seem as dire a choice as Prince Hamlet’s. Fortunately, unlike Hamlet, you are not alone in making a choice. Instead, you have access to the knowledge and advice of compressed air professionals.
Cost remains at the heart of the question of repairing or replacing. Ultimately, the decision becomes an economical one. However, this analysis is actually more complicated than it seems. Comparing pure costs is not comprehensive enough. There’s also lifetime costs, future expenses, and production returns to consider. The best assessment includes the following factors.
Compressor Age:
Just like any machine, air compressors wear out over time. Parts don’t mesh as well, pieces lose stability, and production levels suffer. These natural side effects of age complicate the machine’s response to repairs. Though fixing one section of the machine may be easy, other parts may only support the repair for a short time before they too need to be fixed. Repairing older machines often leads to a cycle of short-term fixes that can quickly add up financially and cause significant overall loss of production time.
Compressor Reliability:
Understanding your air compressor’s history is really important in deciding whether to repair or replace it. Knowing the past character of the machine can be useful when assessing it. Has the compressor had a history of problems since the beginning? Has it needed multiple adjustments to ensure proper function? Or, is this the first time the machine has ever caused major problems? These answers will help categorize your machine’s reliability. The more trustworthy the machine is, the more likely the repair is to last long-term. Compressors with a history of problems or inconsistency bode poorly that a repair will be sufficient. Instead, a new machine might be best.
Compressor Energy Efficiency:
The compressed air industry constantly innovates and improves, often in the form of increased energy efficiency. Air compressors can be very large energy users, in fact Energy Star estimates that up to 75% of the lifetime cost of a compressor comes from its electricity use. If fixing the broken machine will still leave you with a model significantly behind the capabilities of other newer models, replacing may be a more cost-effective solution. When the majority of cost comes from electricity use, you’ll want to minimize the amount of needed electricity.
In general, repair air compressors that are relatively new, reliable performers, or comply with technological advances. These are the machines where investing in the existing machines are most likely to have the greatest return. Whereas, older, unreliable, and inefficient compressors probably will not weather the repairs for long, costing more overall.
If purchasing does seem to be the best option, but your company doesn’t have the required capital, there are ways to defer the cost. CASCO USA offers both leasing options as well as long-term rentals. For more information about when the best times to rent may be, read our blog on the topic here.
Still uncertain what is best for your company? Request help from our compressed air professionals. Sales engineers can talk through the pros and cons of different options with you. They bring their compressor knowledge to spot areas of repair and to help you understand if a replacement is more cost effective. Call us and together we can work through your company’s decision.
Comparing Oil-Injected to Oil-Free Compressors
If you’re in the market for a new air compressor, you have probably seen some models labeled “oil-free.” The specs seem to be the same on these models as on the oil injected models. You may be wondering, what really is the difference between the two? Read on, to understand that question and to understand what model is best for your process.
What does “oil-free” mean?
Contrary to the name, oil-free compressors aren’t actually completely free from oil. Instead, they simply don’t use oil in the compression chamber. This setup limits the amount of oil that could contaminant the compressed air. Unlike traditional designs which inject oil into the compressor element, oil-free models have two-stages to reach the desired compression level. The air cools in an inter-cooler between the chambers, much as oil draws heat from the process in other compressors. With this design, air can be compressed to the same pressure levels as oil-injected models.
Why use oil-free compressors?
Depending on the sensitivity of your process, the oil-free feature may be very important. For instance, both the food and beverage and the pharmaceutical industries could have catastrophic affects if oil were to contaminant the final product. Though oil-free air can be generated through the use of filters with oil-flooded models, many opt instead for an oil-free setup.
Oil-free compressors also generally have lower maintenance costs. Though other areas of the compressor, such as the gearbox, still contain oil and need regular service, the main compression chambers do not. Without oil, there are fewer moving parts and less potential areas for problems.
What are potential downsides?
However, oil-free compressors are not always the best choice for a system. The lifespan of oil-free compressors is much shorter than on oil-injected models, especially in the case of heavy use. Oil-free compressors have less durability and can only tolerate so much use per day. If you plan to run your compressor continuously, an oil-free compressor is probably not best. Also, the lack of lubrication in the compressor chamber results in a very noisy machine, which could cause installation problems.
Choosing a compressor is never an easy task. Buyers must consider plenty of issues and concerns. However, having a basic understanding about different compressor models allows you to specify your search. By knowing what compressor types work with what applications, you will be ready to discuss details and make a more informed decision.
When you are ready to talk details, a CASCO USA representative will be available.
Summer Compressor Cooling Tips
Summer is upon us and with it comes the joys of warm weather. Unfortunately, the hot weather is not particularly easy on your air compressor. The extra heat can cause systems to run slower and less efficiently than other times of the year. Luckily for you, we put together a list of ways to keep your compressed air system ready for summer.
1. Change the oil
The summer heat and humidity can cause oil life to decrease by as much as half! Contaminants such as moisture, acids, and metal particulate enter the oil and decrease its lubricating ability. To keep your compressor in top shape, be sure to change the oil early in the summer.
2. Change the filters
Both clean oil and air filters help the compressor keep stable, run cooler, and work more efficiently. Without proper maintenance on these parts, the overall operating temperature may rise, increasing the likelihood that damaging particles could travel to the airend.
3. Check belts and couplings
Heat damages belts and couplings. Belts with any cracks and wear should be replaced as they are prone to failures. Often times, cracked belts fit loosely, reducing compressor efficiency. Though couplings last longer, they still need to be checked for wear regularly. For best compressor results, maintain these areas.
4. Ensure proper ventilation
Proper ventilation is key not only to maintain adequate operating temperature, but also to keeping the system running smoothly. An overheated system reduces oil life and overall efficiency. Ductwork can be a useful way to remove extra heat from a room and keep air flow sufficient.
5. Maintain the dryer
With summer comes an increase in humidity. This extra moisture means your dryer is working harder and is more important now than in any other season. Proper installation of dryer setups can boost compressor readiness and ensure preparedness for the extra humidity.
6. Check all drains on tanks, dryers, and filters
Once the dryer removes air moisture, the drains are vital in removing the extra water from the system. If a drain is not working, then water could build up in the system and carry downline. Summer creates more condensate, and proper drainage control is key.
Follow these tips to help keep your compressor in top shape through even the hottest days of summer! For even more tips, click here.
Exploring Air Compressors: Scroll Compressors
Part three of our “Exploring Air Compressors” series focuses on Scroll Compressors. Check out the other articles in this series about reciprocating piston compressors and rotary screw compressors.
Scroll Compressors
How does a scroll compressor work?
In a scroll compressor, two spiral elements come together to compress air. The one element remains stationary as the other moves in small circles inside the first element. Because of the movement of the spirals, air becomes trapped in the small air pockets. The rotation of the spiral pushes the air towards the center. As the air moves inward and the spiral continues to circle, smaller and smaller air pockets form, compressing the air. The center of the scroll has a pressure outlet, where the now compressed air travels to the rest of the system. The image to the right demonstrates the spirals’ movement.
What applications should use this?
One great benefit of scroll compressors is that they are 100% oil-free. The spirals never touch during the compression process and as a result do not require lubrication. Any process that needs oil-free air could benefit from a scroll compressor. Industries like food and beverage and pharmaceutical often require clean air for the safety of their processes.
Since scroll compressors are designed with few overlapping parts, they are generally very quiet machines, making them good matches for facilities with noise concerns. Additional benefits to this design of minimal movement are a relatively strong energy efficiency and low maintenance needs. Still, service checks are recommended on at least an annual basis. Depending on a facility’s needs, these benefits could be strong purchasing considerations.
What are examples of scroll compressors?
As with all compressors, process specs such as pressure, flow rate, and electrical service are key components to help decide which model is best. However, scroll compressors tend to be produce smaller flow rates. CASCO USA distributes:
- Anest Iwata (10-40 Hp)
- Powerex
Think a scroll compressor is the best option for you? Discuss details with our engineers.
Exploring Air Compressors: Rotary Screw
This post continues our series “Exploring Air Compressors”. In part one, we discussed the mechanics, applications, and common models of reciprocating piston compressors. Now, we will explore these same questions in regards to the very common rotary screw compressor model.
Rotary Screw
How does a rotary screw compressor work?
A rotary screw compressor uses two rotors for air compression. The specially designed shape of the rotors minimizes the in-between space as the two rotate into each other. The rotors trap the air in the small void and slowly push it to the other side as the rotors circulate into each other.
The air must pass by an inlet port, known as the airend, where oil is injected into the rotors. Once added to the rotors, the air’s space becomes even smaller, increasing the pressure and compression further. While this oil is important for lubrication, sealing air pockets, and absorbing heat, it does have to be drained before the compressed air can travel into the system.
Because of this setup, most rotary screw compressors come standard with an oil removal filter or an oil separator cartridge as part of the compressor package. Keeping these filters in good working order ensures proper air compression and maintains the rest of the system. Regular service includes the periodic replacement of this crucial element.
What applications should use this model?
Rotary Screw compressors have quickly become the standard for generating large amounts of compressed air. Whether you are sandblasting or operating multiple machines in one plant, a rotary screw would work best. Not only are they compatible with a variety of applications, but they also match with a variety of control methods to ensure load efficiency. A process’s specific needs will determine which model to use.
What rotary screw compressors are available?
Common rotary screw compressor sizes range from 25 HP to 300 HP with a variety of flow rates. Models are available, however, as small as 3 HP and as large as 700 HP. There are many varieties to consider, however. CASCO USA carries Kaeser’s entire line of Rotary Screw Compressors and Oil-Free Compressors. For a more detailed explanation of available models, speak with a representative.
To explore more air compressor types, visit our Compressed Air 101: Types of Compressors page.
Exploring Air Compressors: Reciprocating Piston Compressors
There are many different types of air compressors. In fact for a more detailed breakdown of the different types read our Compressed Air 101: Types of Compressors. Every compressor model works slightly differently and has particular applications to which it is best suited. Compressor categories come from the method of air compression. The next few blog posts in this “Exploring Air Compressors” series will each focus on a different compressor category. Each post will explore the mechanics, applications, and common models of a particular compressor type.
Our series begins with the oldest type of air compressor: reciprocating piston compressor.
Reciprocating Piston Compressor
How does a reciprocating piston compressor work?
As one of the simplest and oldest methods of air compression, reciprocating piston compressors are quite ubiquitous. As the name suggests, these compressors use a moving piston to compress air. The movement of the piston shrinks the space around it, forcing the air into a smaller space. With less volume for the air to move around in, the overall air pressure increases.
Piston compressors can be either single acting or double acting, depending on the setup of the compression chamber. Single acting setups work by only drawing and compressing air in one section of the cylinder. The upstroke first draws air in, and then the downstroke compresses it.
Double acting setups allow for every stroke to compress air. As one section of the cylinder’s air is compressed, the other side takes in new air. When the stroke switches direction, the air that was just brought in, is now compressed. New air then enters on the other side. This setup is beneficial for creating more power and strength in a system.
What applications should use this?
Though technology has evolved greatly in the last 50 years or so, reciprocating piston compressors still tend to be the go to compressor for many uses. Many general-purpose applications for compressed air only require a reciprocating piston. Hobbyists, automotive services, and home workshoppers find piston compressors to meet their needs.
The relatively easy set-up of these machines makes maintenance and repairs relatively straight forward. There are not as many interconnected components as some other compressor models, and often units are less costly as well. However, reciprocating piston compressors are not suitable for all applications, and come with certain limitations, such as noise, that should be considered prior to purchase.
What reciprocating piston compressors are available?
Reciprocating piston compressors are generally smaller units, only reaching up to 60 Hp, with the typical range in the 2-30 HP.
CASCO USA stocks:
- Champion reciprocating compressors
- Anest Iwata
For more compressed air reading:
- Exploring Air Compressors Part 2, Rotary Screw Compressors
- Exploring Air Compressors Part 3, Scroll Compressors
- General Air Compressors info
When are equipment rentals the best choice?
Industrial equipment has a huge impact on facilities’ operations. Machines like air compressors and process chillers make daily processes possible. Despite maintenance efforts to keep the machines in their best working order, occasionally new equipment is simply needed. However, sometimes it is just not possible to purchase a brand-new machine. In these cases, equipment rentals may be an excellent avenue to pursue. Renting equipment is especially useful in the case of unexpected failures, upcoming planned outages, or tight capital budgets.
Unexpected Failures
Even the best equipment sometimes fails, and these failures can have a huge impact on company production. Luckily, CASCO USA’s large stock of ready-to-rent air compressors and process chillers can mitigate production downtime. A rental will let you keep meeting production demands despite the unscheduled down time. Emergency rental contracts can be set based on a day-by-day or week-by-week rate. Until you find a permanent fix to the setback, CASCO USA is available to help
Planned Outages
Sometimes scheduled maintenance requires shutting down sections of your system. However, repair work and updates do not necessarily mean all operations have to halt. A temporary rental may fit your system. As needed contracts are available. Our varied inventory easily matches air compressors and chillers to process needs.
Tight Capital Budgets
New equipment can be an expensive initial burden. When the entire cost of a new machine is not available, renting may be a good option. Monthly rental contributions distribute the cost of a full purchase and then ease cash flow. This route may be especially cost-efficient for a set time frame of equipment use. CASCO USA even has options should purchase become a consideration later on.
There are many benefits to renting an air compressor or industrial process chiller. At CASCO USA we understand that each company situation is unique, and we will work to find the best solution for your needs. As with all of our sales, every equipment rental through CASCO USA comes backed by the quality service and expertise of industry professionals. If a problem should arise during your contract period, we will be there to service and help.
Though only you can determine if an equipment rental is the best option, our staff is always available to discuss options in detail. Simply give us a call! You can learn more about our available rental products here.
Ready to request rental service now? Click here.
Addressing Compressed Air Leaks
The largest source of energy loss in any compressed air system is through air leaks. The U.S. Department of Energy estimates that 20-30% of consumed energy is lost to air leaks. Often hard to spot, leaks allow the compressed air to escape, wasting energy and money. Air leaks decrease production capacity and lessen equipment lifespan. To keep systems running their best, follow these tips on leak detection, fixes, and prevention.
Detecting Air Leaks:
Because air is invisible, spotting leaks can sometimes be difficult. However, the following three methods each allow for air leak detection.
Feel and listen
This technique involves traveling the entire length of the system and carefully listening for disturbances. If this method is employed, often the system has to be down. Hearing leaks over the noise of production can be difficult. Because of human hearing limitations, this method typically only detects large leaks.
Soapy Water
This method involves brushing soapy water over the pipes of a system. Any area with a leak will cause the soapy water to bubble. Though very reliable, this method can be time consuming. It also will not provide much detailed information on the leak besides the location.
Ultrasonic
Specialized leak detector equipment pieces pick up the ultrasonic noise associated with the release of compressed air. This method is fast and accurate and can even detect very small leaks. Due to its increased sensitivity, most leak detection programs will employ this method.
Fixing Air Leaks
Once the leaks have been identified, the challenge is to fix it appropriately. Depending on where the leak is, the solution will vary. The most common places for leaks are around connections and equipment. Often times, the piping simply needs to be tightened to increase the seal. Incorrect use of threaded sealant can also be a large area of leakage. If a leak is caused by old or damaged equipment such as a coupling, tube, or fitting, the old version should be replaced as soon as possible.
Prevention/Maintenance
Though leaks in a compressed air system may seem inevitable, preventive measures still exist to decrease leak impact. The best way to prevent future air leaks is to establish a regular leak detection and repair program. This program should involve identification, tracking, repair, and verification, of leaks.
The most important aspect of a successful leak maintenance program is the integration of employees into every step. They are the ones who work with the system on a daily basis. They know the air system better than most people and can more easily spot where problems are. Making sure that employees look out for the system, is the best way to catch and fix leaks before they become too much of an issue.
Merely detecting leaks is not enough for a successful leak prevention program; the leaks actually need to be fixed. Though it seems obvious, many companies spend money on detecting leaks, but never move forward to fix the problems. Generally, the largest leaks should be addressed first in order to see the greatest energy savings.
Effective leak prevention is not just one and done. Instead, facilities should use ongoing efforts to spot problem areas. Compressed air systems run often and undergo constant change, which could lead to new leaks. The best way to stay on top of these changes are to be regularly monitoring the system, and fix leaks before they become too large.
If an energy efficient, cost-effective compressed air system seems like the right direction for your plant, addressing air leaks is a good place to start.
Looking for help in leak detection? Contact a CASCO USA specialist. To learn more about other ways to save money in your compressed air system, read our Energy Rebates blog.
Servicing Air Compressors at CASCO USA
With air compressors, the old adage “an ounce of prevention is worth a pound of cure” certainly holds true. Just as cars require regular maintenance, compressors do too. No one would ever think to drive a car 100,000 miles without getting it checked; yet compressors often run for over 4,000 hours without a service appointment!
Though understanding the amount of work a compressor does might be difficult, it is not impossible. Building on the car comparison from earlier, air compressors have many moving parts. Though the physical machine isn’t traveling anywhere, the parts still complete many miles of work. Similarly, to how mileage on a car marks maintenance intervals, hours on a compressor designate service needs.
Regular maintenance can have huge long-term benefits. A well-serviced air compressor lasts longer, lessening the need for costly equipment repairs or upgrades. Regular maintenance can also help increase current machine efficiency. By catching problems early, system output can be more usable overall.
To ensure the best system attention, schedule regular maintenance visits. Though each installation varies, generally service should occur at a minimum of every 4,000 work hours or once a year. However, the surrounding environment, including level of contaminants, frequency of work, and level of use, have a huge impact on machine wear. These factors affect how service should be scheduled. To determine the best schedule for a particular system, stay in touch with service professionals.
During a preventative maintenance (PM) visit, a technician will check important elements of the machine. Particularly important areas that wear out and will need replaced are filters and belts. A PM often includes valve inspection, component cleaning, and lubrication checks to ensure the best machine performance quality.
Only highly trained technicians should perform service. Luckily, CASCO USA technicians are factory trained and certified; they know the ins and outs of servicing air compressors. When they go to work on a machine, regardless of brand, they come with the skills and background necessary to keep it in working condition. Not only have they learned how to fix known issues, they are skilled troubleshooters as well. They know how to spot and how to prevent potential future problems.
A typical PM service call begins with an inspection of the current state of the machine. Technicians will identify problematic areas as well as address any customer concerns. Whether it’s routine maintenance, an emergency repair, or a diagnostic treatment that’s needed, the technicians at CASCO USA are ready to service your air compressor.
Choosing CASCO USA for air compressor service, means choosing a knowledgeable, reliable source. Our factory-trained technicians have the most up-to-date information to make sure your machines run properly. Whether you have a major unexpected problem or are simply looking for regular maintenance, the service technicians at CASCO USA are the strongest choice.
To request service, call the office nearest you.
Energy Rebates: Save with CASCO USA
Compressed air systems use a lot of energy. According to the US Department of Energy, they account for 10% of all electricity and 16% of all motor energy use in US manufacturing facilities. All this energy consumption can really add up. In fact, a recent Energy Star report estimates that 76% of compressed air’s lifetime cost comes directly from electricity.
Fortunately, a compressed air system doesn’t have to be expensive. Opportunities for saving energy exist in almost every compressed air system! From upgrading inefficient equipment to installing master control systems to reducing air leaks, numerous energy efficiency measures have incentives available. With the right equipment and the best support team, previously high energy costs can be turned into great savings.
At CASCO USA, we work directly with energy companies to maximize incentives. Almost every energy provider has incentive programs in place for increasing efficiency. Some of our past clients have seen energy savings as high as $240,000 annually with an additional $150,000 energy rebate.
What are Energy Incentives?
Energy incentives are monetary rebates offered by energy providers to entice users to purchase more energy efficient products. Programs vary depending on the energy provider, however, they generally work by giving a set amount back to the customer per kilowatt hour saved. Common areas for energy savings include lighting, heating, cooling, and special equipment, as these are the largest sources of energy waste and consumption.
How do they Work?
As population density increases, energy as a resource becomes more valuable. Instead of constructing new power plants, energy providers aim to meet growing demand by making existing uses more efficient.
Often times simple equipment upgrades have the ability for big energy returns. In order to receive the rebate, a company has to show how a new installation will save energy. Though documentation varies from project to project, typically, a customer must establish a baseline of their current system and an analysis of their proposed estimated energy savings. Projects that show a measurable return can expect an energy rebate.
What role does CASCO USA have?
CASCO USA has a team of engineers trained in designing compressed air systems for maximum energy savings. These application engineers understand how systems work, where sources of potential problems are, and how to maximize efficiency, all while improving system reliability.
Conveniently, the first step to any air system upgrade is also the first step required by energy companies: collecting baseline data on the existing system. With this data in hand, potentially any project could be eligible for an incentive.
Our skilled engineers have the equipment and expertise to measure all of the important parameters of your system, including:
- Power (kW)
- Flow (CFM)
- Pressure (PSIG)
CASCO USA is a program/trade ally for the rebate programs offered by most of the energy companies. Our industry experts will work directly with energy providers to ensure receipt of all applicable rebates. CASCO USA handles most of the rebate paper work that includes presenting baseline of existing system, analysis to estimate energy savings for proposed energy efficiency projects and post-project air study to demonstrate actual realized savings, where necessary. In most cases, customer’s only responsibility is to provide handful of documents such as electric bills and W-9s.
Want to start on an energy savings project today? Take the first step and sign up for an air audit here.