Once our customers see what we can do with their compressed air systems, the jobs they ask us to tackle tend to grow.
Working with compressed air requires a wide range of skills from our engineers. In many ways, understanding air compressors and air flow is just the start of a skillset that also includes electrical engineering, plumbing, fabrication and more. So it’s hardly surprising that when our clients are faced with an engineering task they don’t quite know how to resolve, they tend to call us.
That was the case recently, when a client who operated a steelworks called to ask whether we’d be able to modify their small cutter. Our engineers went to investigate.
The first thing that hit them was that steelworks operate on a different level of scale when it comes to describing their equipment. It may have been their small(er) steel cutter, but to any other business it would still have been considered vast.
The cutter was ageing, and that had given the client two options: modify it, to modernise the unit and make it more user friendly. Or replace it. The difference in cost amounted to tens of thousands of pounds.
That’s why, right now, the unit is sat in our workshop, getting some much needed TLC and a significant base unit modification that should keep it fit for purpose for plenty more years.
We’re trialling a new way of recycling oil that cuts waste and increases space.
Work in the compressed air industry and you’ll find oil is a double-edged sword. We need it to lubricate machinery. But at the same time, oil in the pipes of your compressed air system can compromise performance and damage your finished products. It’s fair to say that much of our time is spent eradicating oil from compressed air systems.
If you’ve ever had problems with your compressed air installation, you may know all about the disruptive power of oil. But once it has been removed from the system and you’re back up and running, you probably don’t consider what happens to the oil we remove.
What happens is this: we have to store it, and then dispose of it. Traditionally, we store oil in 20 litre cans, which take up a lot of floorspace. Some are full and awaiting collection, but they’re heavy to transport, costly to dispose of and complicated to recycle. Others are empty and waiting to be filled. In either case they’re still gobbling up valuable room that could be used for something better.
So we were delighted when one of our suppliers came up with a way of replacing the can. Right now, we’re trialling a new ‘wine box’ for our waste oil. Like a wine box, it’s a simple cardboard container that houses a liner into which the oil is poured. In the workshop, empty boxes weigh practically nothing and take up far less space than empty cans.
Once full, they’re lighter and easier to transport, and simpler (and cheaper) to dispose of.
It’s a switch that makes it easier for us to meet our environmental obligations, and one that helps us keep costs down for our clients.
To find out more about the environmental considerations of installing or maintaining a compressed air system, please call 0114 243 2347 or contact us.
When is the very worst time for your factory floor fans to break? As temperatures soared, Algar Air electricians went above and beyond the call of duty to help one local customer cool down.
The thermometer in our workshop was nudging 30°C last week – most definitely not the time for the fans that keep your workforce cool to shudder to a halt. But that’s what happened for one local manufacturer, who saw temperatures on the factory floor start to spiral and the workforce start to wilt.
The fact that our Sheffield electricians were able to get to the factory in question fast, diagnose the problem and fix the fault was a godsend. But as the fans started spinning again, their work wasn’t finished.
One of the engineers was grabbing a quick drink from the water cooler when he noticed a build-up of limescale. Left unchecked, he knew that the water would gradually turn cloudy and taste tainted – and potentially lead to blockages, restricted flows and breakdowns. So the engineers contacted the manufacturer to organise clean-out kits, so the units could be returned to their former glory supplying crisp clean water.
This isn’t an unusual situation. Whether we’re installing a compressed air system, wiring up a new piece of equipment or fixing the pipework, if we spot an additional problem that needs fixing, we’ll fix it.
If you’re a business looking for a South Yorkshire electrical engineer you can rely on to go the extra mile, call us on 0114 243 2347 or contact us.
What do you do when your factory is awash with water? Call us.
Forklifts have a habit of bumping and denting walls and racking. But one local door manufacturer was particularly unlucky when their forklift caught and punctured a main waterline. Cue a major leak that swiftly brought the workshop to a standstill.
The real problem (aside from the unwanted indoor water feature) was that every passing minute was another minute of production lost. So the customer needed more than a callout; they needed a really speedy response. And when they called Algar Air, that’s exactly what they got.
Decades spent installing air compressor equipment has meant that our engineers are also qualified electricians and plumbers, with huge experience in pipework. So it wasn’t simply the fact that our engineer was on site within minutes that the customer really appreciated. It was that fact that the required repairs were completed within half an hour.
You’re eagerly awaiting the arrival of a brand new piece of plant equipment. Then you realise you don’t have the air power to run it…
It’s enough to bring you out in a cold sweat. We were called by a roller shutter door company recently and asked for urgent help. A new washer, dryer and spray booth unit was due for delivery the following week, but our customer had spotted a major problem. Their existing piston air compressor didn’t have the capacity to supply the company’s new machinery.
Without the problem being rectified – and fast – they would need to rearrange the equipment’s commissioning, and that would mean heavy charges, lost time and lost production.
The solution wasn’t an easy one either. Delivering a compressed air system that could supply dry air to all the company’s equipment wasn’t simply a matter of switching a smaller air compressor for a larger one.
Instead, our engineers had to pull out all the stops, installing a full package including a 10HP air compressor, refrigerant dryer, 500 litre air receiver and connecting it all via 169m of 1” pipework.
There was a lot of excitement around the office last week as we received a phone call from Sheffield Theatres to say that one of their Saw had gone down and they needed it fixing urgently. We’d have to work around the Snooker World Championship matches that were being held in Sheffield’s Crucible. Our engineer shot straight down to check over the Unit, tracing the wiring from the Distribution Board to the Isolator and finding a faulty 25amp Overload Relay. On his return visit with the replacement part he was on his way down to the ‘Green Room’ to grab a coffee when he stopped to where he was collared by an “Excuse me – are you allowed in here?” He turned around to find that it was the one and only STEVE DAVIS! Haha they had a good chat and he obviously explained his presence! They walked down to get coffee together where he then met Shaun Murphy as he was about to start playing. He wished him good luck and shook his hand. Star struck and coffee in hand he went back and got the Saw back up and running.
Here’s Stephen Algar carrying out a 20,000 Hour Service on an Avelair 7VSD75 Air Compressor, changing the Air and Oil Filters, Separators and Oil. We also include checking over and re-tensioning the Drive Belts; checking over all electrical and pipework connections; cleaning out Cooler; generally cleaning down and inspecting machine, running-up and testing. We service all sizes of Air Compressors. Give us a call for a quote!
We are pleased to offer our customer’s other services; this month we supplied and installed bespoke Extraction Plenum Chambers for Glue and Solvent work, Extracting to outside of building through Filters. After various consultations with the customer and ourselves we pinned down the exact requirements to suit the customer’s needs for their new department and the correct spec for dealing safely with flammable/toxic gases. We then put together a package that serviced their needs exactly and they now have a non-toxic environment for their staff to work in.
After years of servicing a local Sheffield Steel Firm, looking after their old Broomwade V Major Air Compressors; they have decided to retire them and replace them with brand new Rotary Screws. We are supplying a Hertz Kompressoren Compressor package comprising of 2 off 55kw Rotary Screw Fixed Speed Air Compressors and 1 off 55kw Variable Speed Air Compressor complete with Controller. To follow is an introductory video to Hertz Kompressoren.
The core of our business is servicing and we are pleased to say we service all types of Air Compressors from small Piston Industrial Air Compressors 1.5kw upto 7.5kw on manufacturers like ABAC, Clarkair, Fiac, Fini, Nuair, SIP Industrial, for example. For the Larger Screw Industrial Air Compressors from 4kw to 160kw on manufacturers like Atlas Copco, Avelair, Broomwade, BOGE, Compair, Demag, Fluidair International, Grassair, Hertz Kompressoren, HPC, Hydrovane, Ingersoll Rand, Smart. We can develop a servicing schedule to suit your working environment and the manufacturer’s recommended servicing schedule.
Algar Air also supply a wide range of Gas Compressors / Blowers including Boosters for all types of power generation (this includes the usage of Natural Gas & Landfill Gas.)
We are proud to be working with a local NHS Unit to assist with the design and installation of a new orthotics manufacturing room. Working closely with the specialist specifications of the NHS we produced a proposal designing and building a 6 Station Vacuum Rig with Isolation Valves & Drain Legs complete with the Vacuum Pump and Filtration.
Expansion is on the cards for a Joinery Customer after winning a large contract for Bespoke Doors. It’s always a pleasure to supply new equipment but even more so when it’s due to a company being able to expand. This company assisted by Finance organised for a 11kw/15HP Air Compressor giving 60cfm at 7.5bar on a 500 litre Air Receiver complete with Fridge Dryer, Pre And After Filters and a separate Oil/Water Separator. Working with their schedule of expansion we had the Compressor to them on a 2-3 week delivery, installed it on arrival and they have never looked back since.
We’ve all had that nightmare moment when you’re desperate to complete a job and something fails on you. In this case, a new Customer made contact when their Air Compressor had stopped working. As a Garage, they needed to use their pneumatic tools and blow up tyres everyday so we soon arrived on site with our hire compressor to get them back up and running. This gave us time to weigh up the option for replacement, taking into consideration the location of the compressor (environmental conditions & proximity to staff) and application. We provided them with three options. We soon had an order and a 4kw Air Compressor was supplied and installed within a few days. We’ve now added this customer to our servicing schedule and will be back in touch with them in due course. This is part of our commitment to our customers to be your memory! You never need to remember when your compressor is due for servicing – we’ll do that for you.
We welcome onboard 2 new major customers, one a Large Quarry and the other a Large Metal (Steel & Chrome) Processor.
The first, providing them with a new Compressed Air System including a 30kw Variable Speed Air Compressor complete with a 5 Year Warranty (subject to terms & conditions). The Variable Speed option uses a special drive to control the speed (RPM) of the unit, which in turn saves energy compared to a fixed speed equivalent. Depending on the application the use of a VSD Air Compressor can save a factory a considerable sum in electricity costs.
The second, removing some existing ½” pipework using our IPAF qualified pipework engineers and installing a new 1” pipework as required. Followed by Servicing of their Air Compressors and assisting with Insurance Inspection of said equipment.
Ever wondered what is involved in an overhaul? Here is an example. The work to follow was carried out at a National Waste Recycle Plant.
To carry out remedial work required on the 30kw Air Compressor. To disconnect and remove the Air Compressor from its location; including disconnecting pipework & electrics; removing the internal ducting from the Air Compressor & 2nd Atlas Copco Air Compressor and also removing end of Metal Compressor House. To install 1 off Hire-In Air Compressor. To transport Compressor back to our workshop for repairs, stripping down Compressor at our workshop, removing Airend, Motor and Cooler from Cabinet and prepare for transportation. To industrially clean Cooler. To split, clean out, rebearing and re-seal Airend. To inspect and rebearing Motor. To carry out major service changing Oil, Air Filter, Oil Filter, Separator, Suction Box and Check Valve Seals and Springs, checking all electrical connections and cleaning out Cabinet. To reassemble Air Compressor with Motor, Cooler and overhauled Airend,. To clean down and inspect machine, run-up and test. To transport Air Compressor back to site.
February the month of love, well, one of the 90kw Air Compressors at a Refractory Manufacturer has certainly had plenty of TLC. Our engineers carried out remedial work to the Air Compressor as it was reported to not be working correctly, checking over Compressor, we found the HP side had flamed out, stripping Unit for further inspection, finding Non Return Valve not working, Valves broken, Piston Rods, Piston Rings and Packings worn, all reported back to our customer for approval of remedial work to start.
We measured up Cylinders, Piston Rods and Crossheads to make sure tolerances were within limits and transported Piston Rods & Piston Heads back to our site for re-chroming. (stripping off seized Piston Rods for HP and LP Pistons, cleaning off Carbon and polishing Piston Heads, removing Rings and re-chroming.)
Then the engineers returned to install re-chromed Piston Rods. To cut Piston Rings to size and install Pistons with correct clearance settings. To install Oil Scrapers, Packings, Piston Plate Cover Kits, Big-End Nuts, Bolts and Washers, all associated Gaskets and Seals and grinding out ridges in Cylinders. To install LP Head, finding HP Head blocked, attempting to clean on-site, unable to clean. To transport HP Head back to our Chemical Cleaning Specialists to chemically clean, polish out air ways and water ways. To collect HP Head, transport back to site, install HP Head and full set of Valves complete with Coppers and Rubbers. To remove NRV Unit, cleaning out and installing new Valve, cleaning out sight glasses, running-up and testing.
Due to the Major relocation of a Percussive Down Hole Rock Drilling equipment Manufacturer, our engineers have had 2½ months of on-site co-ordination; seeing the completion of a Large Scale Compressed Air Pipework System with over 299 metres of 2” & 1” Galvanised pipe and working with all on-site Contractors to maintain efficiency and customer output during a difficult manufacturing period. We have supplied hire equipment when required and connected up machinery as and when it had been transported to the new works.
Compressed Air Engineering isn’t all we supply to our customers –for instance, we have had manufactured, per our specification, Lamination Booths for the process of Chemical Carbon Fibre Products complete with Filtrations, for use at an Orthotics Specialist.
We were pleased to see that our long standing customer, who produces Posters to be supplied all over the world, has bought new premises to accommodate their ever expanding business. We have put together a new Compressed Air System comprising of 15kw Air Compressor, suitable Refrigerant Dryer complete with Pre & After Filters to cool the air and remove moisture/contamination and an Oil/water Destroyer to deal with the condensate. All the Compressed Air Equipment is now installed by our first class engineers. Good job boys!
One of our new Packaging Customers this month has taken a full Compressed Air System package from us; we have supplied and installed an 18.5kw Screw Air Compressor producing 110cfm complete with 500 Litre Air Receiver/Tank to store the Compressed Air, Refrigerant Dryer @ 120cfm to remove the moisture including Pre and After Filtration and an Oil/Water Destroyer to deal with the condensate from all of the drains. Good luck to them on their expansion!
This month we have completed a major re-location of Compressed Air Equipment for a Customer of ours who pride themselves on producing precision machined components.
Predominantly supplying to the petrochemical power generation, aerospace and construction industries. As experienced Compressed Air Engineers we were able to manage every step of the relocation work required; supplying the 10ft Steel Container (the new Compressor House); installing 1” pipework from the Ringmain to the new location within the 10ft Steel Container ready for the Avelair Air Compressor and installing Ducting for the ventilation of the exhausted warm air coming from the Air Compressor with weather Louvre to allow Cool air to the Air Compressor.