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  1. Compressors

Compressors

Compressors

  • Do I Need a Piston or Rotary Air Compressors?

    Two of the most popular air compressor configurations are the piston type or reciprocating and rotary screw compressors. There are a few factors that set the two apart based on the way in which they have been set up and the method employed to compress air.

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    Let us start with piston or reciprocating air compressors. These are easily the most commonly used air compressors across the world. They run on the same mechanical principle as the combustion engine. A crank that turns a connecting rod, which in turn moves the piston up and down inside the cylinder head. The inlet valve lets air into the cylinder when the piston is in its lowermost position, the latter is then driven upward to compress the air, converting electric energy to kinetic energy in the process. A typical piston air compressor is oil-cooled, that results in the release of oil residue when the compressed air is discharged.

    Rotary air compressors, on the other hand, are typically configured with two interlocking helical rotors fit with a small gap between them and soaked in an oil bath inside a housing. The inlet valve lets air in, which is compressed in the space between the screws when they turn, reducing the volume and increasing the pressure.

    There are oil-free rotary screw air compressors available as well. In fact, there are some air compressors that even come equipped with just one screw, but again, these are not very common.

    Here we have a list of factors compared which will let you determine which of the two types of compressors might suit your needs better.

    Rotary air compressors and piston compressors - Comparison

    1. Maintenance and wear and tear – In piston compressors, the wear and tear is greater due to a large number of moving parts. This results in more maintenance compared to a rotary screw processor. However, because of the simple mechanical setup of a piston compressor, it is easier to maintain and fix, despite the greater frequency of maintenance required.

     

    1. Operating temperature, noise and vibration – Typically, a rotary compressor has lower operating temperatures than piston compressors. Friction is the lead cause for this, because the rotors in the screw compressor don’t come in contact, whereas piston rings are in constant contact with the cylinder walls, creating greater friction and raising temperatures. The former also generates less noise and vibrates lesser than the latter due to the same reason.

     

    1. Air flow and operation time – Because of the high temperatures in a piston type compressor, it cannot be run non-stop due to the risk of overheating. Furthermore it is also typically run at only 50% of its total CFM or air flow capacity. The rotary screw compressor, however, is capable of being run continuously. You can also purchase a rotary screw compressor that is rated as close as possible to your required air flow capacity rather than one rated at double the capacity.

     

    1. Space required and energy efficiency – Since rotary screws are encased next to one another in one chamber, the whole setup usually takes up less space than a piston compressor which requires cylinder heads for the vertical movement of the pistons. The former are also more energy efficient than the latter with fewer transmission losses as well. However, the effects are only discernable in compressors of 20 HP or more horsepower.

     

    1. Pressure ratio and volume – The compression range is much greater on a piston configuration when compared to a rotary screw type. There is also more flexibility in terms of pressure ratio and capacity. However, in rotary compressors, while the flexibility is limited, the comparative volume capacity is much greater than that of reciprocating air compressors.

     

    1. Oil carry-over – Piston compressors typically discharge more oil into the stream of compressed air than rotary screw compressors do. Due to the high-friction moving parts, wear-and-tear leads to more oil carry-over than in rotary screw compressors.

     

    1. Price – Due to the above mentioned factors, the cost of a piston compressor is a lot lesser than that of a rotary screw compressor.

    Now that you know the major differences between the two type of compressors – piston and rotary, and what advantages and disadvantages either brings to the table, you can make an informed investment. Before you decide either way, make sure to check out some great deals and one of the widest ranges of compressors available at our online store. If you have more questions, our air compressor experts at Compressor World will be more than happy to help you out.

  • A Buyer's Guide to Rotary Vane Air Compressors

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    Buying an air compressor can be a difficult given the variety available today. There are so many options when it comes to configuration, size, capacity and brand that potential buyers can end up confused about which compressor is right for their business.

    Introduction

    Rotary pumps are widely used across industries and applications, from supercharging and power steering in cars, to providing the pressure for soda dispensers and coffee machines.

    Here is a brief look at the mechanical structure of rotary vane air compressors.

    The rotary vane compressor comprises of a cylindrical rotor that is placed inside a cavity or a housing. The rotor also has a few grooves or slots inside which the vanes are placed. The rotor is intentionally placed in a position where it almost comes into contact with the housing it is encased in. This off-center placement allows the vanes to be pushed out through the use of centrifugal force, allowing air to be trapped between them. This air is then reduced in volume and pressurized by the rotating motion of the rotor.

    At Compressor World, we want our customers to get the most value for their money and this can happen only when you are rightly informed about any product we offer. So we have prepared a rotary vane air compressor buying guide that will help you consider important factors you should know before buying rotary vane compressors.

    Read this guide before you invest your money, and understand which factors matter most in your context and to decide if rotary vane compressors will suit your needs best or not.

     

    Factors to consider when buying a rotary vane compressor

    Duty cycle

    The duty cycle is essentially the capacity for the compressor to run at peak performance before it starts to overheat or massively deteriorate. Typically measured as a percentage, the duty cycle is an extremely important factor to consider when purchasing a compressor. If you need something heavy duty to run for extended periods of time without issues, a high duty cycle percentage is a must.

    Not all compressor configurations allow for a high duty cycle percentage. However, the rotary vane typically offers close to a 100% duty cycle figure. Lower revolutions and operating temperatures coupled with liquid cooling mean the rotary vane compressor can typically run at full tilt without causing excessive temperatures or wear in the moving parts.

    Maintenance

    The major maintenance for rotary vane air compressors comes from replacing the oil, cleaning out the oil filters and air filters, and replacing both the aforementioned filters at a certain point in time after continuous use. None of these components are too expensive, and they are relatively easily available and easy to replace. The rotary vane air compressor also tends to have a long operational life if its maintenance plans and schedules are followed accurately. The vanes are the main moving components in a rotary vane, and usually the moving components face the most wear. Not in this case though, because rotary vane compressors have oil films to protect the vanes. This means they don’t come in direct contact with either the grooves or the inside of the rotor during the compression process. As long as you ensure basic and timely maintenance for your compressor as mentioned earlier happens, you won’t need to worry about any short term expenditure that involve replacing or repairing moving parts.

    Long term costs

    We have already established that rotary vane compressors are relatively cheap to maintain. They are also low on power consumption, which is a good thing economically in the long run. A tight, leak-free air seal results in less air loss. Other types of compressors usually need to compensate for air loss at higher rotating speeds, but this is not the case with rotary vane air compressors. The speeds at which the rotor turns here is relatively low, typically between 1000-1500 RPM based on the compressor make and manufacturer. This results in lower power consumption figures of course, but also has the added benefit of lower temperatures and lesser noise from the device.

    Initial costs

    While rotary vane compressors are typically more expensive than regular piston compressors, if you want to run your compressor smoothly over long periods, the performance of vane compressors definitely justify the initial cost. At Compressor World we offer both finance solutions and a price match guarantee on a wide range of rotary vane air compressors.

    Popular rotary vane compressor brands

    Here are some of the most popular, reliable and respected brands that manufacture rotary vane air compressors.

    • Mattei Compressors
    • Hydrovane
    • Champion
    • Chicago Pneumatic Air Compressors

     

    Now that you are up to speed on what a rotary vane compressor is, how it works, and what its primary attributes and advantages are, you will know exactly what you are getting for the money you put in to buying one. If you want the best rotary vane air compressors out there, you can only go to one place – Compressor World.

    Check out our wide variety of compressors today, and if you have any doubts or need further assistance to decide the right compressor, contact our experts today.

  • 7 Top Selling Air Compressor Brands in 2016

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    Air compressors are used in myriad applications and in various industries. The air compressor industry is growing from strength to strength every year due to this versatility of uses and the degree to which they reduce the effort required in jobs they are applied for. Some of the most popular industries that employ air compressors on a regular basis include –

    • Manufacturing
    • Agriculture
    • Automotive
    • Food and Beverage
    • Medicine
    • Pharmacy
    • Energy
    • Art and sculpture
    • Climate control, and more

    This widespread usage has resulted in the air compressor industry being valued by Global Market Insights at $5 billion as of 2015, and an expected growth of 3.2% Compound Annual Growth Rate (CAGR) for the period of 2016-2023. This means, the projected size of the market is expected to exceed $39 billion by 2023.

    All this progress is being driven by the innovations and technologies developed and marketed by top brands that make up the air compressor industry. Here are the most popular air compressor brands in 2016 that have continued to impress with their high-quality products that have established them as reputed names in the world of air compressors.

    1. Chicago Pneumatic Air Compressors – The Chicago Pneumatic Tool Company was established by visionary John W. Duntley in 1894. They deal in a variety of tools and compressors. Chicago Pneumatic air compressors can be found anywhere in the world these days, and in 2016, CP announced the lending of support to five colleges by providing them with industrial tools and insights into their benefits.
    2. Ingersoll Rand Compressors – Another company that has been around for over a century. Don’t be surprised if you find an Ingersoll Rand air compressor in just about any location on the globe, be it the Americas, Europe, the Middle East, Africa, or in the Asia Pacific region. This global multi-billion dollar company is definitely one of the biggest in the world.
    3. Quincy Compressors – Quincy air compressors have near instantaneous recognition in the industry due their 95 years of work as air compressor manufacturers and long-standing experience and expertise in the industry. Quincy recently announced the acquisition of Scale Technologies to strengthen their network and reach in the northeastern region of the United States.
    4. Champion – With over 800 distribution outlets and service facilities in the US, Champion air compressor, an 85-year-old company, is dedicated and focused towards producing quality air compressors. A particular expert in producing reciprocating compressors and rotary screw compressor systems, Champion is definitely up there among the biggest names in the sector.
    5. KORE Compressor – A relatively new player in the air compressor game, Kore was established somewhat recently – in the year 2000. Don’t let its age fool you though, because with each Kore air compressor customers receive quality, and technologically advanced piece of machinery.
    6. ALMiG Air Compressors – ALMiG Kompressoren GmbH is a Germany based global air compressor powerhouse. ALMiG has been all about the compressor ever since its establishment in 1923, and has remained true to its marquee product ever since. Today ALMiG has a 200 strong team operating out of the same location in Köngen where the company was first established so many years ago.
    7. Atlas Copco Compressors – A Swedish company based out of Stockholm, the company that manufactures the famous Atlas Copco air compressor began operations in 1873. Atlas Copco recently announced their Q3 results for 2016 which saw them establish an 11% increase in orders, a 3% increase in revenue, and an adjusted operating profit margin of nearly 20% from their operations that span 180 countries worldwide and employ 43000 individuals across all ventures.

    The aforementioned are the biggest and best in the air compressor manufacturing segment from across the globe, and we here at Compressor World stock their most famed and loved products. As one of the leading distributors for top-notch air compressor manufacturers, we too share the vision of delivering nothing but the best in air compressors. You can be assured that we have a solution for you, no matter how unique your need is. Our team of experts are always ready to answer your questions while you compare and decide which compressor would be the best fit for you! We also ensure express delivery and local services at your location. Get in touch with us today.

  • How to Choose the Right Air Compressor in 6 Simple Steps

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    Air compressors are versatile machines and perform a variety of tasks when attached to pneumatic tools. They produce more torque and power and last longer since their moving parts are fewer, when compared to electric power tools. They have many applications, types and capacities, which can be confusing if you are not familiar with the world of compressors!

    At Compressor World, we want customers to be able to clearly understand products before they make any decisions. So, here is a brief air compressor buying guide that will help you explore six decisive factors. Now you can decide which compressor suits your unique needs best.

    1. Air compressor grades

    Compressors come in various grades based on capacity and applications. You need to be aware of them! Consumer grade compressors are for the house or a small garage workshop, and can handle low pressures, mostly using a single tool at a time. Contractor Grade compressors are portable, sometimes wheeled, or can be mounted on a cart or small vehicle and will enable use of small tools on work-sites, like nail-guns and roadside repair tools. Commercial air compressors provide a steady supply of compressed air, are heavy duty, and have more detailed features. These compressors can power multiple tools at higher pressure continuously and are used in industries, right from factory shop floors to oil rigs and ships.

    1. Type of compressor: Single or two stage?

    Single-stage air compressors are low capacity and the smaller models can be moved manually. These are for applications like air brushing, for small shops and homes. They have varying capacities and may also include a small storage tank for compressed air in larger models.

    Two-stage air compressors are for garages and manufacturing facilities and can provide enough power to simultaneously run several air tools. These models compress the air twice, have storage tanks, and are therefore priced higher.Tank sizes can go up to 200 gallons and beyond, and hold a lot of compressed air, which lets you reduce the input power consumption.

    1. Capacity and delivery of the air compressor

    Your air compressor’s capacity and delivery will depend on these factors:

    PSI – Pounds per Square Inch:  A higher PSI is more compressed air for a given tank size.

    CFM –The amount of air delivery possible in Cubic Feet per Minute. A higher CFM is more practical when the number of tools being used increase.

    HP – The amount of power produced by the compressor motor. A higher horsepower produces greater PSI.

    Tank Size: A larger tank size will hold a higher PSI for longer durations of time. You must check these specifications carefully when comparing models.

    1. Rotary screw or piston compressors?

    Piston air compressors are most common in the automotive service industry, and will generally supply a lower air output delivery, as well as lower air quality. These also generate more noise and operate at higher temperatures. They may require more maintenance for a given duty cycle. They also consume comparatively more power for a given output. Choose a rotary screw compressor for more reliability, better quality air, lower energy cost and lesser maintenance. In the long run these will compensate for any additional costs.

    1. Power source of the air compressor

    Electric air compressors are very common, quieter and can be used where there is a regular electricity supply, and in places where ventilation is a consideration.  However, they tend to be less powerful compared to fossil-fuel driven compressors, and have constraints in outdoor use. Large capacity electricity driven air compressors will need a 400V or 3 phase supply transformer. These would, then, not be portable units.

    A petrol engine driven air compressor would be lighter, quieter and less expensive to buy than its diesel driven counterpart, while providing more control over its engine. However they do not output similar torque or power than an equally rated diesel alternative, and have higher running costs including maintenance.

    Diesel air compressors are movable, work in adverse weather conditions outdoors, and are more powerful and heavy duty. Their robust nature and lower fuel cost and maintenance compensate for the higher initial cost. The disadvantages are more noise and toxicity of exhaust fumes.

    1. Choosing the right air compressor manufacturer and supplier

    While there are many manufacturers, your new compressor will need to be reliable, and through its service life it requires good support to keep it functioning optimally.

    Here the choice narrows down to a manufacturer with a long standing in the business and reliability of their machines. A good manufacturing process entails the use of higher quality materials, and greater attention to detail and design which pay back the slightly increased initial cost in the designed service life of your compressor. Along with this, finding and entrusting shipping and local support to a dependable supplier takes additional worries off your back!

    At Compressor World, we know that purchasing the right compressed air system is no simple task. Therefore we have an online store with express delivery for our customers. You can easily compare a host of air compressors before making that final buy. We also have experts ready to answer your questions so you can have assistance throughout your purchase journey. In fact our confidence in our air compressor experts is so high, we have a 100% money back guarantee! Contact us today!

  • 4 Types of Rotary Screw Compressors That Actually Add Value

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    Rotary screw air compressors are one of the most commonly used type of air compressor in industries today. A cornerstone of the manufacturing world, rotary screw compressors come in two basic kinds, oil-injected and oil-free. In oil-injected rotary screw compressors oil is injected into the screw unit when compression takes place, and later the oil is siphoned out by an oil separator. There is a miniscule amount of oil carryover, or oil that is passed through the machine along with the compressed air, and is missed by the separator. The oil cools the air being compressed and keeps the screw lubricated. These type of compressors are cheaper that the oil-free variety, produce less noise, and are less complicated to maintain.

    However, in some situations and specific industry applications, the oil carryover, however negligible, is a problem. This is where the second kind, oilless rotary screw air compressors, come in. In these type of compressors, the air is compressed in two stages and passed through an intercooler to help bring down the temperature between the two stages. Otherwise the compressed air rises to extremely high temperatures. These compressors are more specialized and come at a higher cost. They also typically produce more noise and are high-maintenance.

    While these are the two basic types of rotary screw compressors, there are further categories based on the layout and mechanics of compressors.

    Four sub categories of widely applicable rotary screw compressors

    1. Base mounted – A base mounted rotary screw compressor is a standalone device typically used in situations where the space available is lacking and a constant flow of compressed air is required. Base mounted systems typically don’t come with an air receiver tank. You can also get base mounted with air dryer configurations if required. One of the byproducts of air compression is water vapor, and in certain industries, the water vapor is detrimental to the environment or the product being manufactured. In these cases an air dryer is used to remove water vapor from the compressed air produced by the compressor.
    1. Tank mounted – Tank mounted rotary screw air compressors are rotary screw compressor systems that are mounted to an air receiver tank. The receiver tank stores compressed air for instances where the amount of compressed air required rises. Typically a receiver also has an air drying function, removing vapor from the compressed air. Receiver tanks also reduce pulsation, and come equipped with a pressure gauge and pressure release valve.
    1. Total air system – Total air systems or TAS, combine the space saving ability of the base mounted compressor and the purification and air storage facility of the tank mounted compressor. The compressor, tank, dryer and even a filtration system are all integrated into one compact package in a total air system. Total air systems provide increased convenience, and because all the auxiliary functions are bundled in to one unit, the time taken to install and installation costs are both greatly reduced.
    1. Variable speed – A relatively recent breakthrough in air compression technology, variable speed rotary screw air compressors are a type of rotary screw compressor that come equipped with a motor control drive that regulates the speed of the unit. This means the rotations per minute or RPM of the compressor can be changed on the basis of needs or load. This improves the energy efficiency of the compressor, helps keep power surges under control, and deliver more precise temperature and humidity control.

    These are the four major sub categories of rotary screw air compressors, and as you can see, they provide distinct functions and abilities that set each one of them apart. The different abilities mean each has specific advantages unique to them that make them particularly suitable for certain applications.

    These types of air compressors are further classified by capacity, voltage, horsepower, tank capacity (where applicable) and configuration. Now that you know what each category of compressor brings to the table, take advantage of the wide variety available here at Compressor World and choose the perfect rotary screw air compressor to match your needs.

  • Using Oilless Scroll Air Compressors

    Who uses Oilless Scroll Air Compressors?

    What is a oilless scroll air compressor?

    A scroll air compressor is a compressor that generates air by using two teflon coated plates, separated with a tip seal.  These plates bring atmospheric air and pressurize the air to system pressure of 50-145 PSIG.  Typically, their are two pumps, a low pressure (115 psi) and high pressure pump (145 psi).

     

    Oilless Scroll Air Compressor with 30 Gall Air Tank Oilless Scroll Air Compressor with 30 Gall Air Tank

    Where are oilless scroll air compressors installed?

    Scroll pumps are used for a variety of applications;

    • Medical Air Applications
    • Laboratory Air
    • Remediation
    • Pharmaceutical Air
    • Transportation (Air Brakes)
    • Railroad (Air Brakes)
    • Painting
    • Manufacturing
    • Breathing Air
    • Farming
    • Brewing/Beverage
    • Pneumatic Controls

    Why used Oilless Scroll vs. a Oilless Piston Compressors?

    Both types of pumps generate oilless air, the biggest difference between the oilless scroll and oilless piston would be the duty cycle and noise level.  Oilless scroll compressors are rated for 100% duty cycle where oilless piston pumps are generally rated for 60%-70%.  Oilless scroll compressors are also very quiet vs. the piston.  We wouldn’t recommend installing the oilless pump near any sleeping quarters in a hospital!

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  • Air Compressors with Air Dryer

    The internet has made buying air compressor equipment very easy. The key is understanding which system to buy. Challenge the team of experts, ask them why the integrated air dryer is better than a separate standing dryer. Ask if you can have a internal bypass installed within the cabinet of the compressor. Ask the compressor manufacturer to give you the cost of a replacement dryer and lead time.

    Integrated air dryers have a purpose and do save space but they can be costly. So do your research when buying the screw compressor with air dryer.

    Rotary Screw Air Compressor with Air Dryer

    A lot of rotary screw compressor brands install the air dryer outside of the screw cabinet. These dryers run cooler, are easier to service and cost less to replace. Quincy Compressors and Chicago Pneumatic Air Compressors offer very reliable screw air compressors with air dryers and tanks. The most popular sizes are the 7.5 hp rotary screw compressors, 10 hp screw compressors and 15 hp screw air compressor systems.

    These rotary compressor systems including the air dryer and tank make it very easy to install, where you only require a plumber and electrician. Continue reading

  • Air Compressors and How They Work

    The practice of workshops using a central power source for driving tools isn’t new. Over the years, what’s changed though, is the use of air compressors in place of the belts and shafts that were driven mechanically to route power around the workspace. The underlying physics remains the same, i.e., when a certain volume of gas increases within an enclosure, the pressure increases, thereby producing power.

    Modern day air compressors are compact, portable and efficient, and are available in a variety of designs and configurations to suit different operational requirements. So, be it at the gas stations round the corner, or major manufacturing plants, air compressors can be found in a wide range of situations today. Continue reading

  • KORE Compressors - Air Compressors

    Kore Compressor Kore Compressor

    Compressor World now offers a new line of air compressors from Kore Compressors. Their line offers a full range of rotary screw air compressors, with load/no load controls as well as variable speed drive controllers.

    KORE Compressors offer the following standard features:

    • Wye Delta/Reduced voltage starting. This will reduce the start up amp by 1/3 (vs. across the line starting)
    • Phase Protection
    • Sound Enclosures
    • PLC Controllers
    • TEFC Drive Motors

    Many of the features stated above are optional from other compressor suppliers. These features are great for the smaller air compressor applications, 15 to 100 Horsepower. KORE Compressors are stocked in Massachusetts for quick shipments.

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  • Rotary Screw Air Compressors: Analyzing With a Fine-Toothed Comb

    Rotary screw air compressors are one of the most popular choices of industrial air compressors. They are known as positive displacement compressors, and are a good choice for industrial applications, many the majority of the rotary screw compressors are 50 hp and below. To find out if rotary screw air compressor is the rind kind of compressor for your plant, it's important to know the advantages and disadvantages that it offers.

    Rotary Screw Air Compressors
    As I had described in my previous blog on Rotary Screw Air Compressor Basics, rotary screw air compressors use two rotors or helical screws to compress air. The shapes of these rotors are unique and designed such that when they turn in the opposite directions, they offer very limited clearance in-between. Air is sucked in from one end, trapped between the rotating rotors and then pushed through to the other pressure-side end, thereby producing compressed air.

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