No matter your industry, you likely have a need for air compressors. For everything from pharmaceutical applications to food and beverage processes, air compressors provide the necessary function of pressurizing air. That air can then be used to power different equipment and systems, such as nail guns, blast equipment, conveyor systems, painting equipment, and so much more.
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When considering air compressors, you will note they fall into two main categories — oil-flooded and oil-free. Both categories differ in terms of operation, applications, benefits, and downsides. Understanding how each kind of air compressor works is key so that you can choose the best one for your specific needs.
Every air compressor — oil-flooded or oil-free — features numerous components that effectively pressurize air and turn it into power. Without lubrication, they fail to operate, and your air compressor will be useless. Like dozens of other machinery, an oiled air compressor uses oil to provide lubrication to the various parts of the system.
These air compressors can operate on two different types of oil — mineral and synthetic. Mineral oil is the product of a petroleum refining process, while synthetic oil is a laboratory creation.
Mineral oil is typically the better option for small-to-medium compressors that don’t operate continuously. A synthetic lubricant is more suitable for industrial air compressors because it provides more protection against overheating due to its wider temperature variations.
During operation, an oil-flooded reciprocating air compressor pulls in air via a piston. Then, the air is pushed out of the chamber and compressed into a storage tank. Here, oil is critical to ensure the piston has enough lubrication to move — in an oil-flooded rotary screw compressor, the oil also lubricates the rotary screws, which help draw in the air. When the storage tank maxes out, the air compressor turns off, and you can use the pressurized air to power various tools and gear.
To provide the necessary lubrication, an oil air compressor includes a pump, which you can fill with mineral or synthetic oil as you would for a vehicle. Periodically, you must check the oil levels and oil filter to ensure the pump is in working order. Additionally, scheduled oil changes and proper routine maintenance are required for optimal performance.
Any industry that needs pressurized air for its operations can use oiled air compressors so long as contamination is not a concern. A few examples of industries that use these air compressors include automotive, railroad, machinery manufacturing, metal fabrication, and woodworking.
Oil-flooded air compressors offer several advantages for owners and operators. These units feature durable and rugged construction, an important consideration when longevity is a primary concern. Because they can extend the time between air compressor replacements, they could be more cost-effective in the long run. Quiet operation can also make oil-flooded models a better option for industrial or commercial environments where noise prevention is essential.
Minimal heat generation is another advantage of this air compressor type. The diminished risk of overheating lowers the damage potential and enhances safety.
Many companies prefer oil-flooded air compressors because of their relative technical simplicity. Operations that prefer handling equipment upkeep in-house won’t need to spend as much time training their team on the machinery. They also won’t need to incur the costs of hiring outside labor.
A disadvantage of lubricated air compressors is that operators and maintenance crews must monitor them regularly to ensure they have sufficient oil. It’s also crucial to change the oil and filters at the appropriate intervals. Because they tend to be large, bulky machines, it’s often more difficult to move them between locations.
Some owners have concerns about oil contamination, although installing additional filters can often mitigate this issue.
While an oil-free air compressor works almost identically to an oil air compressor, it does not use oil for lubrication. Instead, it is either constructed to prevent mechanical contact or relies on an option other than oil for lubrication. Most often, users keep their oil-free air compressors operational with water or a Teflon coating.
One difference in how an oil-free air compressor works in comparison to its oil-based alternative is that it moves the air through an initial compressor element to cool it down. There is no lubricating medium to cool the air naturally, so an intercooler is required to keep the temperature low. The second difference is that after compression, the air moves into an aftercooler to cool further. Finally, it can be used to power your equipment.
In industries where contamination is strictly prohibited and can be costly, oil-free air compressors are crucial. For example, food and beverage manufacturing, electronics, and pharmaceutical companies must keep their products pure, and any possibility of physical oil contamination or air contamination from running an oil-flooded air compressor is not allowed.
The upfront cost of an air compressor matters for many businesses when shopping for these machines. Oil-free models sometimes, but not always, have a lower upfront purchase price depending on model, type, size, and horsepower. But, because oil-free air compressors require less preventative maintenance than oil-flooded compressors, the overall total cost of ownership is often lower.
For many businesses, perhaps the most important oil-free air compressor advantage is their ability to deliver contaminate-free, clean air with no traces of oil. This factor is meaningful to doctors or dentists who need to create a sterile environment for their patients. Or pharmaceutical, electronics, and food and beverage companies that have strict cleanliness standards.
Reduced maintenance requirements are also an attractive feature for companies that may not have the time or labor force for these practices.
The smaller size of these units can be a positive feature for organizations seeking a mobile compressed air solution they can apply in different areas of their facility.
Because most oil-free compressors aren’t well-suited for heavy-duty environments, they’re not the best choice for demanding industrial applications requiring continuous or extended use. Overuse could also require more frequent maintenance and repairs and shorten the equipment’s life span.
Depending on the type of oil-free air compressor, the increased noise and heat output can be an issue for organizations where comfort, safety and concentration on job duties are top priorities. Companies may need to invest in powerful industrial cooling equipment to combat the heat. Also keep in mind that oil-free compressors these days have more advanced technologies and design features than previous years, so they’re not as loud as they used to be.
Oil-Free and oil-flooded air compressors operate differently, meaning you may need one over the other for your applications. As you make comparisons, consider the distinctions between each compressor type. Even with all of the above information, you may need help determining which option is ideal for your business.
Below are a few more aspects of air compressors to help you make the best decision possible:
Ultimately, your selection comes down to your business’s unique needs, making it a smart idea to work with a professional team to make the process easier for you.
Depending on your applications and industry, choosing an air compressor can be a crucial decision. Aside from considering the pointers above to guide your choice, you should also make sure to work with a knowledgeable compressed air solutions provider. C.H. Reed’s Compressed Air Team has the experience and expertise to help you find the best equipment option so you can accomplish your goals.
For decades, C.H. Reed has worked with industrial companies and manufacturers throughout the Mid-Atlantic to provide them with process and equipment improvements. Whether your business requires compressed air, paint finishing or fluid handling or industrial blowers sales, service, or solutions, we can help you meet your goals.
Get started by browsing our service areas or contacting us with our online form for a quote. We look forward to partnering with you!
Air compression is essential in several industries, including the pharmaceutical, automotive, food and beverage, and agricultural sectors. There are several air compressor variations; for instance, some handle heavy-duty applications better than others. However, you can typically place air compressors into two overarching categories: oil-lubricated compressors and oil-free compressors.
All air compressors have moving parts. You must lubricate these moving parts to avoid damaging your air compressor. If you do not adequately lubricate your compressor, it will fail to function correctly. Oil is the most common lubrication material used for machinery, and traditional oil-lubed compressors utilize this tried-and-true medium.
Oiled compressors are rugged and durable, and their oil usage makes them ideal for industrial applications. They tend to produce a lot of heat, but the oil acts as a coolant.
Oil-lubricated compressors are versatile and reliable, but they have some drawbacks. For one, they require a lot of maintenance, and operators have to check oil levels and change the oil and oil filters on a regular basis. Additionally, their large size makes them impossible to transport, so you have to permanently install them at a single location.
The most glaring drawback of using oil-lubricated compressors is the risk of oil contamination. The oil used to lubricate, seal, and cool the machine leaves oil content in the compressed air that you must remove via separation or filtration. In industries where air purity is critical (particularly in sterile environments), even the tiniest drop of oil risks contamination.
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Oil contamination can cause product spoilage, rework, production downtime, and even damage to your brand’s reputation if you do not correct the issue. This is where oil-free compressors come into play…
Oil-free compressors use an alternative sealing, cooling, or lubrication medium, such as water, eliminating the risks and associated costs of oil contamination. Companies use oil-free compressors for applications where even the slightest bit of oil carry-over is unacceptable.
For example, pharmaceutical manufacturing companies must have no hydrocarbons in their products or the air in their production facilities. The same is true for food and beverage companies, such as bottling companies and food packaging manufacturers, because air comes into direct contact with their products.
Here is a list of industries and applications that typically require oil-free air compressors to avoid oil contamination.
Medical
Pharmaceutical
Food & Beverage
Life Science
Chemical
Power Generation
There are a few myths floating around that people use to discredit oil-free air compressors. We’re going to debunk a few of these myths.
We can’t deny that oil-free compressors used to be much noisier than their traditional oil-lubricated counterparts. However, modern oil-free compressors are not nearly as loud as people make them out to be. Today’s oil-free compressors utilize direct-drive, dual-piston pumps and sound-reducing technology, making noise a non-issue.
The biggest argument against oil-free compressors is their relatively short life expectancy. Again, this may have been the case back in the day, but today’s oil-free compressor lifespans are no longer an issue.
Oil-free technology has advanced significantly, allowing oil-free compressors to run cooler and last longer. Plus, they require less maintenance than oil compressors. However, you will likely have to replace the airend on an oil-free compressor before you have to replace the airend on a well-maintained oil-flooded compressor.
While it is true that oil acts as a heat-transfer material and keeps compressors cool, the dual-pump designs of oil-free compressors allow them to achieve the desired CFM/PSI in half the number of revolutions as it takes an oil compressor.
Air compressors cover several platforms, including reciprocating, scroll, and centrifugal, and each platform has distinct advantages and applications. However, these are some general advantages and disadvantages of oil-flooded and oil-free compressors.
Better suited for
heavy-duty
and
industrial applications
Operate longer before needing an airend replacement
Very heavy; permanently installed at a single location
Require far more maintenance and need to be oiled regularly
More expensive to lubricate
Oil contaminates
the surrounding air
Compact and portable design
Don’t require manual lubrication
Easier to operate
Suited for applications jeopardized by
oil contamination
Better for non-commercial purposes
More expensive
Can’t handle
heavy-duty
applications as well as oil-injected compressors
Will probably require an airend replacement sooner than an oil-injected compressor
While both oil-flooded and oil-free air compressors have pros and cons, in the end, your application will most likely determine which one is better suited for you. If oil contamination could put your business at risk, then an oil-free compressor is the way to go. If you need an air compressor for a heavy-duty, industrial application, an oiled air compressor is the one for you.
C&B Equipment is a licensed distributor of both oil-flooded and oil-free Gardner Denver air compressors. We can help you determine which air compressor is the right one for your business. Reach out to us today and consult with one of our air compressor experts!
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