Oil-free air compressors are currently widely used in industries with high requirements for compressed air, such as medicine, precision electronics, and chips. In the glass blowing industry, compressed air also plays a vital role. Next, let&#;s learn about the applications of oil-free air compressors in the glass production industry? Why should the glass production industry choose oil-free air compressors?
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The importance of oil-free air compressors to glass production
First, let&#;s understand the process of glass blowing. The molding of glass bottles mainly relies on high temperature and pressure to blow-mold preheated glass balls or tubes into the required shape. During this process, if the compressed air contains oil or impurities, they will adhere to the glass surface, causing defects, uneven color and other problems in the product. These defects not only affect the appearance of the product, but may also affect the sealing and durability of the product.
To solve this problem, the glass blowing industry needs clean compressed air. The biggest feature of an oil-free air compressor is that it can provide 100% oil-free pure compressed air. Oil-free water-lubricated air compressors use water for lubrication during the compression process. The compressed air does not come into contact with lubricating oil, ensuring the purity of the output air.
Specific applications of compressed air in glass factories
1, The air compressor provides combustion-supporting air for the combustion of glass liquid in the melting kiln of the production line.
2, Air compressors are used in media transportation processes such as coke powder pipeline transportation and injection.
3, Air compressors are used to provide compressed air to pneumatic equipment in various workshops to control equipment or instrument actuators.
4, When the bag or air filter cartridge of the dust collector needs to be backflushed and cleaned, the compressed air provided by the air compressor also needs to be used.
The benefits of choosing an oil-free air compressor
Additionally, oil-free air compressors offer several other advantages that make them ideal for the glass blowing industry.
1, High stability: The oil-free air compressor adopts a fully enclosed design, which avoids the impact of the external environment on the compressed air and ensures the stability of the output air. This helps to improve the molding quality of glass bottles and reduce the scrap rate during the production process.
2, Easy maintenance: Due to the simple internal structure of the oil-free air compressor, maintenance work is relatively simple. Regular maintenance work such as replacing filters can effectively extend the service life of the equipment and reduce operating costs.
3, Energy saving and environmental protection: Oil-free air compressor adopts advanced energy-saving technology, which can effectively reduce energy consumption. At the same time, because the exhaust gas it emits does not contain oil, it has a small impact on the environment and is in line with the green development concept of modern industry.
4, High reliability: Oil-free air compressors use high-quality materials and components and have high reliability. This helps reduce downtime during production and improves productivity.
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Why Choose OFAC oil free Air Compressor?
1, original Mitsui&#;s technology, can replace Mitsui&#;s air end 1:1; 2, 100% oil-free, 100% 0 emission; 3, highest precision air end manufacturer in China. 4, air end faulty rate can be nearly 0; 5, consumable parts only include air filter and water filter. 6, only 1/2 price than dry oil-free type.
Compressed air is critical to blow moulding production and the opportunities to improve supply side efficiency are highly prevalent.
Measurement and recording of actual pressure flow inside the production equipment can assess the actual performance of the compressed air system. This identifies any areas where compressed air problems are causing limitations on productivity and quality of production, the improvement of which in turn can lead to lower energy use costs and increased production rates.
All blow moulding processes require stable compressed air pressure delivered to the moulding machine to control quality and maintain productivity. In most blow moulding processes, compressed air is used to inflate the parison, a tube-like piece of plastic with a hole in one end through which compressed air can pass. The compressed air also cools the part after inflation to final form, but prior to ejection from the mould.
In PET bottle blowing, high-speed machines use compressed air to produce bottles at rates of over 20,000 bottles per hour. The rate of pressure rise becomes dependent upon the pressure differential driving the flow from the air inlet of the machine to the cavity. The higher the inlet pressure the faster the rate of pressure rise.
Increasing the system pressure is a common way to maximise productivity and still produce good product. Unfortunately, higher pressure leads to wasteful artificial demand, elevated compressor energy and maintenance costs, and inefficiency in managing the system.
Blowing the part as quickly as possible leads to very high rates of flow in supply components creating high pressure drop. A blow machine running 24,000, 500 mL bottles per hour can consume 90 m3/min depending upon setup creating significant pressure drop in the headers and filters delivering the air. In order to make acceptable bottles with this level of pressure drop the system has to operate at dramatically higher than necessary pressure.
This higher than necessary pressure means each bottle requires a greater volume of air, and because the header pressure is elevated to increase the inflation pressure differential, the blow pressure continues to rise to higher than required pressure after the bottle is fully moulded. For every bar of pressure increase above the required blow pressure, the volumetric flow required increases by the volume of the bottle. For example, one bar in excess pressure for a 500 mL bottle times the production rate equates to 1.5 m3/min in artificial demand.
The most common compressor for achieving these pressures is a 3-stage reciprocating machine which uses valves to control the flow of air through the stages. At these higher pressures the temperatures are higher, increasing the stress and wear on critical components. Where it was possible to substantially decrease the discharge pressures, maintenance cycles are extended by as much as 25&#;30%. Power is also reduced at the lower discharge pressures by a ratio of 1% energy reduction for every 5% pressure reduction. A reduction of 700 kPa or 16% will mean about a 3% energy reduction at the compressors.
The first step in capturing efficiency opportunities is to minimise the pressure drop within the moulding machines, which normally requires removing and/or replacing pneumatic components with those of higher flow capability. The regulators and filters are critical items and must be examined closely by measuring the pressure drop while the machine is blowing bottles. Localised storage receivers can minimise pressure drop by supporting the very high rates of flow during each blow cycle with stored air. This storage must be located as close to the point of consumption as possible; for example, it must be tied into the pneumatic circuit after the filter and regulator to be of any value.
Managing this level of pressure change requires significant modifications in the approach to system management. While compressed air storage tanks can be expensive, maximising the storage is essential with most compressed air systems as the lack of appropriate storage is even more costly if additional compressors are required to run part loaded to deal with the rates of pressure change.
An appropriate automation system which calculates the rate of pressure change and makes intelligent decisions regarding the appropriate supply-side response can make a significant difference in energy costs and reduce compressor cycling, wear and motor starts. Avoiding unnecessary compressor starts due to the rate of change can mean saving many thousands of dollars in energy costs per year.
Kaishan Compressors offers an assessment and advisory service for upgrading, replacement, design and installation of new systems to match production demands.
Contact us to discuss your requirements of hydrostatic pressure test. Our experienced sales team can help you identify the options that best suit your needs.