We spend a lot of time with clients helping them improve the purity of their compressed air by removing contaminants, and one of the ways we do that is with dryers. We’ve spoken on numerous occasions about the differences between refrigerant dryers and desiccant dryers. For most industrial applications refrigerant dryers will be a viable choice, but that’s not always the case.

Refrigerant dryers work by cooling the water vapour within a compressed air system to below 3°C so that it reaches dew point at the dryer. There, as the vapour condenses into water, it can easily be drained from the system.

But what happens if parts of your system are already cold enough for the vapour to turn to dew? Here, a refrigerant dryer can be ineffective, because there may be water condensing and collecting throughout the system, not just at the dryer.

That’s a problem because not all of that water will work its way to the dryer. Some of it may return to the compressor where it can increase wear and reduce efficiency. And some of it will head to the other end of the system and (potentially) contaminate the product being manufactured.

Worse still, if yours is the sort of factory or workshop where winter temperatures might dip below freezing, the water within the compressed air system can freeze too. That can cause damage throughout your compressed air system, from the compressor itself, to pipes and filters.

So a refrigerant dryer may not always be the ideal option. In such situations, desiccant dryers, which remove moisture using absorbent materials and which are generally unaffected by ambient temperature, should be selected instead.

Need help in choosing the right dryer for your compressed air system? Talk to Algar Air, the compressed air specialists, on 0114 243 2347.

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Chances are your company’s energy bill is one of its most significant costs, and your air compressor, whilst essential to keeping production going, is also going to be a significant contributor to those energy costs. So how can you lower them?

One option is to turn down the pressure of your air compressor. The other is to simply switch to a smaller compressor. One of them (within reason) may be a viable option. One of them definitely won’t be.

Pressure drop

On the face of it, it sounds reasonable enough. What’s to stop you nipping a few psi off your compressor’s output so that running costs are lower? The problem with this is that the rest of your compressed air equipment – your filters, dryers and separators – are designed for a system operating optimally. Drop the power and your dryer or filters, optimised for a system running at a higher psi, may now be prone to clogging, reducing efficiency, increasing the level of moisture and contaminants in the system, and increasing compressor wear.

Downsizing

Naturally, your air compressor still needs to be able to deliver power to the tools and processes that need it. But sometimes, a business will build in far more capacity than is required. Sometimes, strategic changes will see alternative power sources used for some tools. And sometimes, what starts as the primary power source becomes a secondary one.

When that happens, the air compressor you have may be significantly larger than the air compressor you need.

Downsizing – by buying a smaller new or used air compressor can cut energy costs and free valuable workspace. And it’s always the preferable option to reducing the pressure.

Need help in downsizing your compressed air system? Talk to Algar Air, the compressed air specialists, on 0114 243 2347.

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We spend a lot of time talking about the benefits of compressed air to all sorts of clients from all sorts of business backgrounds. We know how versatile compressed air systems can be, but it’s only when you analyse where your clients come from that you realise just how versatile.

We took a snapshot of the customers we supplied with air compressors, receivers and separators over the summer, and the results were something of an eye-opener.

Breaking down the figures

As you might expect, manufacturing and industrial processes make up the lion’s share of our market, but within that market there’s a huge diversity of businesses. Over summer, our air compressor equipment went to companies as diverse as tool manufacturers, industrial engineers, steel fabricators and CNC equipment manufacturers.

There’s a huge variety in the scale of the processes too, and in the air power required to accomplish them. For every modest air compressor required to power the manufacture of workwear or process special steels, there’s a far larger air compressor being put to work in the aggregates sector.

At the more unusual end of the manufacturing spectrum, some of our compressed air equipment is now busy manufacturing silverware. Some of it is even helping to make figure skating blades.

Beyond air compressors

It hasn’t been all air compressors. As an example, we’ve sent a desiccant dyer to a crankshaft manufacturer, an oil/water separator to a steel fabricator, a fridge dryer to a refractory manufacturer (that makes high temperature materials for kilns and reactors) and a vacuum pump to a building products manufacturer.

Beyond manufacturing

We’ve already mentioned the aggregates supplier, but there are plenty of other applications for our air compressor equipment beyond manufacturing. Over summer, we’ve supplied bus stations, universities and printers too, to name but a few.

We’d love to supply your air power too. So if you’re part of any of the industries listed above, or you work in something else entirely but want help in creating the right compressed air system for you, call us now on 0114 243 2347, or contact us.

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*Please note photos are for illustrative purposes only – we may not stock / provide these exact models.

 
We speak to lots of customers who, when Googling questions about their air compressor, have been directed to a forum. Ask Google about air compressor oil and you will inevitably come across forums full of compressor users who have been happily pouring motor oil into the equipment for years without a problem.

They’re lucky. Automotive oils contain detergents and additives. In a car engine those additions help prevent corrosion, wear, foaming, sludge build up and more. Put them in an air compressor, however, and they will result in the build-up of harmful carbon deposits. Add water to the mix (as screw compressors inevitably do) and the oil will emulsify, effectively reducing or removing its protective and lubricating qualities.

And that’s before we consider the issue of the manufacturer’s warranty, and the fact that no manufacturer will uphold a warranty on an air compressor that has had motor engine oil in its system.

How compressor oils differ from engine oil

Air compressor oil is detergent, sulphur and additive free, so it won’t cause damaging build ups on the compressor’s valves and other surfaces. An air compressor manufacturer will always recommend a specific brand of oil, and if you are changing the oil yourself we would encourage sticking to this recommendation to avoid invalidating your warranty.

Oil changes are part and parcel of our maintenance service contracts, so if your business relies on an air compressor, talk to us about a service plan that will keep the oil topped up (with the correct oil) and keep every other part in good working order. Call us now on 0114 243 2347, or contact us.

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For many workshops, space is at a premium, so it can be tempting to find innovative ways of storing your equipment to free up a little more usable space. That was the challenge for one of our clients recently who asked whether mounting their small air compressor upside down and out of the way would cause problems.

On the face of it, it was a perfectly reasonable question. Theirs is not an air compressor that uses oil, so there could be no issues with lubricants collecting in the wrong parts of the compressor. And just to add to their reasons, they felt they had more freedom for their air compressor lines with the compressor inverted. Yet even with an oil-free compressor, mounting should always be the right way up.

This is for a number of reasons. An upside down compressor can place unexpected stress forces on parts of the machine and cause additional wear. An upside down motor can cause heat dissipation issues, and risk overheating. And even on its side, you’ll find greater piston ring wear.

So, if you are struggling for space and want to explore your air compressor mounting options, have a read of this piece, which covers the optimum siting of air compressors in the workplace but ensure your compressor remains orientated the right way up. Then, if you are still struggling to find the ideal position to site your air compressor equipment, call us on 0114 243 2347, or contact us.

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On the face of it, it seems like the simplest of questions. Surely, your air compressor needs to go where there’s space and where no one is likely to be obstructed by it. But there’s rather more to choosing the prime position for your compressor than that:

1. Room temperature

For the coolant in your air compressor to do its job, the compressor needs to operate in an environment between 4° and 40°C. At or beyond those extremes, your air compressor coolant is likely to be unable to work effectively enough, and the machine may shut down. It will also require more maintenance to compensate for the increased wear.

Ideally, therefore, your air compressor should be sited in a cool area.

2. Air circulation

Air compressors generate significant heat, and they can quickly heat the area around them. That’s especially the case when the air compressor is in an enclosed space, where the hot air vented from the compressor is likely to be sucked back into the machine, creating a heating cycle that can cause the problems noted above.

Ensure your compressor has the air space suggested by the manufacturer, and if you are unsure what that is, talk to us.

3. Accessibility

Your air compressor is going to need regular servicing and, over time, it’s likely that some fairly significant components will need replacing. That requires space to work, ideally around three feet on every side.

4. Noise

Air compressors aren’t quiet, and if employees are in the vicinity all day it could be a source of frustration and even harm. One solution is to site the compressor away from the workforce; another is to provide ear defenders for those closest to the compressor. And a third is to create a soundproof booth or room and place the compressor in there.

5. Proximity

You don’t have to place your air compressor at the heart of the production floor, especially if any of the above will cause problems. However, the more ducting you introduce the more power your air compressor needs to generate and the larger the overall system in terms of maintenance and fault-finding. In larger operations it is perhaps inevitable that there will be significant distances between a compressor and the various tools it feeds, but it is important to eliminate as much needless distance as possible.

Need help finding the right place to site your air compressor equipment? Call us now on 0114 243 2347, or contact us.

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Why does my air compressor need a filter?

It may not be immediately obvious, but each cubic foot of compressed air can contain millions of dirt particles, water and oil. This contamination of the air is most noticeable when you are using your compressor for something which demands a fine finish – paint spraying, for example. Unfiltered (or when your filter isn’t performing as it should) you’ll notice the spray finish has a dappled appearance, caused by dirt and water in the air flow. Filter such particles out, and you’ll find the finish improves enormously.

  >  Do you need help with inline filtration?

But filtering isn’t only required where the application demands a fine finish. Particles in the air can cause additional wear on the compressor and your air tools. They can coat valves and other parts of the machine. They use more energy and cost more to run (because the motor has to work harder to force the air around the system). And they increase the likelihood of a breakdown and/or the frequency of servicing.

Filtering solid particles

We have spoken about separating oil and water from your compressed air system previously, so in this piece we shall focus on filtering solids (although a filter may also remove some oil and condensate).

   •  Particulate (or coarse) filters scrub the air of contaminants measuring 5 to 40 microns
   •  Fine and micro filters remove particles smaller than 1 micron
   •  Activated carbon filters capture oil vapours
   •  Sterile filters scrub the air of germs and would typically be used in pharmaceutical, medical, food or beverage applications

As you might expect, the tiering of filters is important. Place a micro filter upstream of a coarse filter and it will immediately become clogged, restricting air flow and reducing the effectiveness of the compressor. Instead, the coarse filter should come first in the air stream, collecting the larger particles before enabling the micro and other filters to do their jobs.

Maintaining the filter

Like the filter in your coffee machine or vacuum cleaner, as particles gather, so the machine performs less effectively. It’s important, therefore, to replace filters periodically. Precisely how often the filter will need replacing depends on the compressor, the filter and the application. You compressor may be fitted with a sensor which may monitor air flow at the filter and alert you when pressure starts to drop due to clogging.

Our maintenance service contracts ensure filters are replaced before they become clogged enough to reduce performance, or impact energy costs and compressor wear. To talk to us about keeping your air compressor equipment in prime condition, please call us on 0114 243 2347, or contact us.

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Air pressure is the force with which the air generated by your air compressor is delivered by the air tool. It’s important to be able to control the pressure – think of the warnings on the air tools at your local garage, telling you not to try using them on your child’s bike tyres or paddling pool. That’s because the pressure is far greater than those items can withstand. Try using the air tool to inflate a child’s rubber ring, for example, and it won’t blow it up; it’ll blow it apart.

Pressure is measured in psi or atmospheric pressure (Bar). 1 Bar is roughly 15 psi and most air tools operate between 2 and 6 Bar (22-35 psi). Many heavier duty air tools will operate at the upper end of that range – with sanders, drills and the like frequently requiring 6 Bar.

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Sprayers, however, typically require considerably less pressure. Too high, and the air compressor will atomise the spray to too great a degree, so the paint never reaches the surface of the application.

Pressure vs consumption

The energy efficiency of your air compressor is affected by a number of factors, and the pressure at which the compressor is required to work is a major one. The higher the pressure, the harder the air compressor motor has to work and the more energy it will use.

To reduce costs, consider a variable speed air compressor, which will automatically adjust its performance depending on usage, so there’s always airflow and air pressure when you need it, but without operating at full capacity when there’s little or no demand on the system.

Need help finding the right air compressor for your business? Call Algar Air now on 0114 243 2347, or contact us.

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*Please note photos are for illustrative purposes only – we may not stock / provide these exact models.

 
Talk about extremes. We’ve already explored the challenges of a frozen air compressor this month. Now we’re at the other end of the spectrum.

High temperatures are never good news for an air compressor. The act of compressing air creates heat (just think of how hot the nozzle of your air tool or joints in the pipework can get) so inviting even more heat into the equation is never a great idea.

That heat can come from numerous sources, including the ambient temperature, or from clogged and dirty parts which can restrict airflow and add to friction.

  >  How to prepare your compressed air system for winter

The problems with hot air

 
An air compressor that runs too hot too long creates lots of issues. Most obviously, it can overheat and breakdown. Yet often before that happens, damage will have been caused in a variety of other ways. Many air tools need cool, clean air. Hot air creates moisture and moisture causes rust when it remains in the machine, and can ruin end products when it’s spat out of the air tool. That would have been particularly damaging in this case as the businesses dealt with food containers. Keeping them contaminant-free was essential.

Keeping the air cool and dry is aided by refrigerant driers, but these can only operate effectively within certain tolerances. Like blowing a hairdryer into your refrigerator at home, when the air’s just too hot, attempts at cooling simply won’t work.

And then there’s the issue of wear. An air compressor that’s running hot is working harder than it should. That means it will burn though its oil coolant faster, and parts are likely to wear quicker. So in addition to risking breakdown, it’ll be costing you more to run.

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Taking the heat off

 
Our client was running two air compressors, one 75kW and one 45kW, that had been in place for around seven years. Naturally, taking both offline at the same time wasn’t an option as that would have meant production downtime. So instead we hired out a 55kW air compressor to take the place of each compressor as we removed it for maintenance.

Once the rental unit was in place we decommissioned the 75kW air compressor, removed it from site and stripped it down for a full chemical clean. Once the clean was finished we put everything back together and reinstalled it on site, before repeating the process with the 45kW air compressor.

The process took several days, but all the while our 55kW compressor was ensuring that the company always had the cool, clean air power it needed.

Are your air compressors running hot? Talk to us now about the maintenance and air compressor hire that can keep production running. Call Algar Air now on 0114 243 2347, or contact us.

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We had a call from someone recently who used an air compressor for airbrushing. Could they, they asked, use their existing compressor for other tools?

Our answer was that it depends. If they were using a standard air compressor then yes, providing the air pressure and air consumption of the tool they were going to buy was within the delivery capabilities of the compressor, they would be able to use any tool.

The problem, however, was they were actually using a small air compressor specifically designed for airbrushing. Whilst that might be fine for additional low key activities like inflating a bike tyre or paddling pool, it simply wouldn’t generate the pressure and airflow necessary to power larger tools.

So now, they keep the airbrushing compressor for airbrushing alone, and they’ve got a new, 24l, 9.6CFM air compressor to handle their workshop tools.

To find out more about choosing the right air tools for the right air compressors, talk to us now on 0114 243 2347.

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It can be a tricky thing, timing the servicing of your air compressor equipment. On the one hand, you know that servicing your air compressor will keep things running smoothly and help protect against breakdowns. On the other, there’s never a good time to switch the machinery off and allow the engineers to do their ‘thing’.

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That was the case for a client in Lincoln recently, who asked us to carry out a major service on a 55kw Hertz HSC55 air compressor. Their issue, however, was that they couldn’t afford the downtime caused by us arriving during a production period. So we timed the service to coincide with their lunchtime break.

We sent two engineers to ensure the work would be covered in the allotted time. As staff headed off for lunch they set to work, and as staff were returning to their stations our engineers were packing tools away, job all done.

It’s something the client really appreciated, because it meant that the service of the air compressor equipment didn’t cost them a moment of valuable production time.

Can we do the same for you? Ask us about air compressor servicing to suit your schedule on 0114 243 2347.

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If you’ve ever called out someone about a repair to your car, washing machine or computer, you’ll know there’s a kind of common language of repairs. There’s the rubbing the chin and wincing while the engineer says “It’ll cost you.” There’s the “we can’t be with you until sometime next year” issue, and there’s the perennial favourite: “you can’t get the parts.”

Whichever you get, it can leave you pulling your hair out and questioning your faith in whoever it is you’ve called.

  >  Air compressor repairs & remedial work
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So here’s an example of an approach we took with a customer recently that illustrates just how hard we work to create a different perception.

We were called by a tool manufacturing company. The client was having problems with a Hydrovane HV15 air compressor, which had broken down and had put a halt to production. Our engineers attended quickly and discovered a broken spider coupling and a separator that was passing oil.

This really was one of those occasions where we needed to order new parts to complete the repair and, as you might expect, no air compressor repair company can carry every part for every air compressor.

But there was something we could do.

We carried out a quick, temporary repair. It wouldn’t last forever, but it did at least enable production to continue safely until we could return with the right parts.

And that’s the difference between our approach to compressed air system repairs and others you may have come across. Instead of throwing up our hands and saying there’s nothing to be done until the right part arrives, we explore what can be done.

And if that sounds like your sort of compressed air engineers, give us a call on 0114 243 2347.

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It’s funny how jobs seem to run in cycles isn’t it? Recently, for example, we seem to have had a run on replacement refrigeration dryers, supplying three new ones (110cfm, 159cfm and 210cfm units, if you’re counting) in the last month alone.

Like any piece of equipment, dryers have a finite lifespan. Regular servicing and maintenance will extend that life, but eventually it will be time to replace – and it’s vital that replacement happens fast.

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That’s because, for many industries, a constant, regular supply of compressed air isn’t enough. From food to pharmaceuticals to paint spraying and precision air tools, the quality of the air matters every bit as much as pressure and flow.

In compressed air systems, ensuring quality effectively comes down to removing contaminants (usually oil and water) and that’s where your filters, separators and dryers play their part.

Refrigeration dryers work by cooling the warm air generated by compression until it condenses, where the moisture can then be trapped and removed. Without drying (and filtration and separation) the moisture remains in the system until it is spat out at the business end of the system by your air compressor tools, where it can damage paint finishes or contaminate food.

Even if your compressed air system uses dryers that have years of life left in them, it’s important to ensure they’re working properly. So for servicing or replacement refrigeration dryers, talk to us now on 0114 243 2347.

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Cars (and vans, trucks and buses) killed 1780 people in the UK last year. Actually, that’s not true. 1780 people died on people’s roads last year. Many cars were involved. But the car was at fault in only a fraction of them. It’s a similar story with air compressors.

Whether it’s an internal combustion engine or an air compressor, the thing itself is rarely at issue. Where problems arise, it’s invariably a result of one of the following:

     •  Incorrect installation
     •  Poor / no training
     •  Poor / no servicing or maintenance
     •  Airborne particulates

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Every year or 12,500 miles, whichever arrives sooner, I have to take my car for a service. I know I could leave it, but to do so would increase the risk of more serious (and expensive) issues. It makes the car that bit more efficient, so some of what I spend on the service I recoup in greater efficiency. And I protect my warranty.

Following the right procedures is just as vital with an air compressor. First, it needs correct installation by compressed air experts who can ensure that, from pipework to electricals to tools and connectors, all is as it should be.

Installing the right filters protects product quality and scrubs particulates from the air. Maintenance and servicing protects airflow and pressure, and ensures filters keep performing.
And proper training ensures that correct operating procedures are followed, that issues are spotted, and that users know the limits of their understanding – so they avoid problems caused by tampering and ‘having a go’ at repairing issues.

What we’re saying, in this roundabout way, is that air compressors are not dangerous, but people – or at least, their decisions – can be. So to keep your air compressor safe, get it professionally installed, keep it well maintained, and don’t let anyone use it who isn’t trained.

For installation, servicing and maintenance of your compressed air equipment, call us on 0114 243 2347.

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Let’s take a look at some of the more unusual uses for air compressors.

Art Work

Air compressors are commonly used in garages and auto shops but not just for pumping tyres. Their versatility makes them very useful when it comes to more cosmetic work. Spray painting is much simpler with an air compressor and you get a much evener coat of paint.

While this is undoubtedly useful for cars and other vehicles air compressors are now getting more of a following in the art world. They can be used to paint furniture and be used on canvas as well, all you need is a spray gun attachment and you can use your air compressor in a whole new way.

Cleaning

You wouldn’t normally associate cleaning with an air compressor, would you? But while it might not seem like it, an air compressor can be a cleaning marvel on all sorts of objects and in all kinds of surroundings. With a blow gun attachment, you can transform your air compressor into a powerful cleaning device, with just a squeeze of the handle you can blow dust, dirt, and grime away.

This is very useful for cleaning machinery and getting into small spaces but it can also be used to clean up wood shavings and much more. You might be able to achieve similar results with a pressure washer but the intensity of the water can easily cause damage, so a gentler compressed air cleaning method can be the better option.

Gardening

At first glance, an air compressor might not seem like the best gardening tool and while you can’t use it to plant flowers it certainly does have its uses. We’ve already talked about how an air compressor can be used for painting and while it will certainly make painting your fence easier an air compressor can also help with another important gardening job.

With the right attachments, you can use an air compressor to blow away leaves and debris which can be a huge help and save you money on a leaf blower. This can also be used indoors to sweep up and clean floors as well.

Inflation

OK, so inflation might not seem like an unusual choice, after all, we all know air compressors can be used to inflate tyres. But why stick to just tyres? Most people don’t realise that they can also use their air compressor to inflate a range of other items.

Inflatable toys, furniture, mattresses and swimming pools can all be inflated with an air compressor and it’s a much quicker and less tiring way to do it as well. You might need a regulator attachment in order to inflate certain items safely especially if it’s for objects like balloons which will burst if the pressure is too high.

Snow Machines

Saving the most unusual to last! Snow machines can be all sorts of fun at parties and special events and with an air compressor, you won’t need to hire one. Now getting everything together to create your own mini-snowstorm will take a while and some practice but there are plenty of guides online for you to take a look at.

Want help in finding the right air compressor for your application? Talk to Algar Air on 0114 243 2347.

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Air compressors have long been a feature of the automotive production process. So it’s no surprise to find that the market for air compressor accessories such as hose reels, pressure gauges and air filters is buoyant. What is new is where demand is coming from.

New market research reveals that although Western Europe is the second largest air compressor accessories market, the real growth is coming from those just ahead and behind of Europe in the rankings.

In China and India – the so-called APEJ market that currently sits top of the global trends – rapid industrialisation has driven the automotive market. It’s a similar story in Latin America, where major manufacturers see opportunities for big expansion.

If there’s a lesson for Europe’s automotive air compressor suppliers (of whom Algar Air is one) it’s that no market can be relied on to maintain its position in the global hierarchy. Growth means exploring opportunities for international trade, and diversification into other air compressor-dependent sectors – something we’ve long been pursuing.

Want to explore air compressor options for your automotive business? Talk to us on 0114 243 2347, or contact us.

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An air receiver is an essential part of any compressed air system. A receiver is basically a tank that acts like a reservoir that feeds your air compressor. When demand on the system is high, the air receiver ensures there’s enough air to keep supplying your air tools at the correct pressure and flow rate. When there’s a little slack in the system it provides a space for the excess air to go, again protecting consistency of air flow.

In addition, air receivers can help remove moisture from your compressed air system. Moisture is a natural by-product of the heating effect of squeezing air molecules together in a confined space. Without an air receiver (and without other filters and dryers), more of that moisture typically finds its way into tubes, tools and the finished product.

But the air receiver provides a low pressure area in which air can cool and condense, ensuring your tools receive a cleaner supply of air.

Which air receiver do I need?

The standard rule of thumb is that your air receiver tank capacity should be 6-10 times the flow rate of the system. So, for example, if your air compressor has a rating of 25 scfm, the receiver tank should be capable of storing a minimum of 150 cubic feet.

Every receiver tank should have a pressure gauge and a pressure relief valve (to vent excess air) which should be set at 10% above the working pressure of the system. And there should be a drain facility to remove condensed water from the system. Each of the air receivers supplied by Algar Air has a pressure relief valve and an auto drain feature.

To find out more about air receivers, or to discuss which is the right air receiver for your specific application, talk to us on 0114 243 2347, or contact us.

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When you’ve been involved with compressed air as long as we have, you can find yourself confronted by the same old urban myths and conventional ‘wisdom’. So here, in no particular order, are the 4 compressed air myths we seem to spend most time challenging:

Compressed air is an inefficient source of power

Actually, providing your compressed air system is an equal match for the job you’re asking of it, it’s one of the most efficient sources of power for any business. Typically, where businesses have experienced problems with low pressure or inconsistent power, it’s because their air compressor is being asked to do too much.

The solution is to ask a compressed air consultant to design a system that will deliver all you need of it, rather than gradually building an ad hoc system that eventually becomes overloaded.

Compressed air is expensive

Leave your car engine running or the heating on 24/7 and costs will mount up. It’s the same with compressed air. As with any energy source, there is a cost, but you can keep those costs down with a well designed and well maintained system. From addressing issues of geography (i.e. not having your air compressor a mile away from the tools it’s powering), to addressing leaks, your compressed air system can be made to be as cost efficient as any other form of energy.

Compressed air is dirty

Only in a poorly designed system. It’s true that moisture and oil vapour tend to be natural by-products of using compressed air, and left untreated that could have an impact on anything from food production to paint spraying.

But with the right filters and dryers in place, and with a regular regime of servicing and maintenance, compressed air could help give your products an exceptional finish, entirely free from contaminants.

Compressed air is complicated

It doesn’t have to be, especially when you have an expert team to help. So if talk of airflows, pressure and purity leave your head in a spin, ask us to design, supply and maintain a compliant compressed air system that does everything you need of it, simply.

To make a start, call us on 0114 243 2347, or contact us.

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If you’ve ever touched the air compressor head or any of its various pipes and tubes after it’s been running for a while, chances are you won’t do it again. Things can get pretty hot before your compressor reaches cut-out. But why is that? And is it normal?

To answer that second question first, yes, it’s completely normal. The reason for that is your air compressor has two major heat generators. The first is the electric motor, the heat from which will be conducted to other parts of the compressor.

The second (and most powerful) source of heat is the act of air compression itself. Squeezing air molecules together creates friction, and a by-product of friction is heat. Friction is the reason rubbing your hands together creates warmth. And it’s the reason matches light when struck against a matchbox.

The act of forcing air together creates a lot of friction and a lot of heat, which is conducted through the air compressor’s metal parts. Providing your air compressor cut out is operating as it should, there should be no issue with the heat generated, as it will dissipate during cut out.

Only if your air compressor isn’t cutting out after its regular duty cycle should you seek help. If that’s the case, or if you’re worried about any other aspect of your air compressor equipment, please call us on 0114 243 2347, or contact us.

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Whether you’re a small workshop running a single air tool, or a large manufacturing business running an entire factory floor’s worth of tools from an industrial compressor, there’s one simple fact of life in choosing the right equipment for the job. You need to be able to generate more air power than your tools require.

But how do you calculate the required air for your application(s) without overengineering things to such an extent that you end up paying to generate airflow you don’t need?

Follow these steps as a general guide only. For specific applications, call us first:

Q: Are you running one tool at a time from your air compressor, or several?
If you’ll be running one tool at a time, check the required CFM (cubic feet per minute) ratings of each of the air tools you’ll be planning to use. You’ll find the information in product descriptions (if you haven’t yet bought the tools) or in the instructions (if you have). For the purposes of this exercise, go with the highest CFM figure.

If you’ll be running more than one tool from the same compressor, you’ll need to add all the CFM figures together and multiply by 1.2 to account for the power loss inherent in running more than one tool simultaneously.

Q: Will you be running tools continuously?
The CFM ratings you’re working to will usually be averages, calculated on the assumption you’ll be using air compressor power in short bursts. That’s fine if you’re powering something like a nail gun, but not if you’re running something continuously, such as a conveyor belt.

So for tools requiring continuous running, multiply their CFMs by 4.

Q: Are you using extension hoses?
The closer you can place the tool to the air compressor, the less chance there is of losing any significant amount of air flow through hoses, connectors, filters etc. If you’re operating on a large scale, with tools some distance from the central compressor, you’ll need to factor in airflow lost over distance.

As that figure will vary depending on the hoses and connectors used, call us on 0114 243 2347 for help in calculating your requirements.

Tank size?
Now, you should have a CFM figure, telling you how much air flow you’ll need to be able to produce. To equate that to air compressor tank size, multiply the figure by 6, and opt for the air compressor with the tank size that meets or is closest to (but above) it.

Need help finding the right air compressor for your application? Talk to Algar Air’s engineers now on 0114 243 2347, or contact us.

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If you’ve used air compressors to any extent, chances are you’ll be familiar with the gurgling and spitting that happens at the business-end of the machine as your compressor produces water as well as air. You may also be familiar with the way moisture can, for example, throw tyres off balance, ruin your paint spraying or sandblasting, or simply reduce the air pressure.

Water is bad news for compressed air, but where does it come from, and how can you get rid of it?

In all but the most arid places on earth, water is a frustrating by-product of compressing air. It occurs because the air your compressor sucks in includes water vapour. The act of compression causes the water vapour to heat up, filling your airlines with steam, which then condenses as it cools.

Filters will remove some of the moisture, but for precision applications like paint spraying, that frequently won’t be enough.

The power of dryers

 
Dryers remove far more moisture than filters. We operate two types:

Refrigerant dryers (almost counter-intuitively) accelerate the cooling process. They ensure more water vapour condenses quickly, where it can be collected and removed before it has the chance to reach the drills, sprays, guns and conveyors at the end of your air lines.

Desiccant dryers use ultra-absorbent materials to remove even more moisture, creating near-zero humidity by removing moisture to -70°C dewpoint.

To find out which drying system is right for your air compressor application, call us on 0114 243 2347, or contact us.

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The air compressors we supply and install are designed for a range of uses, and as a result they have a range of power outputs, providing enough horsepower for a single tool, or for a whole factory floor of them. But horsepower in the air compressor industry has proved to be a rather unreliable measure, so how can you ensure the equipment you choose has the power you need?

The uncertainty stems from years of manufacturing practises that saw the horsepower quoted in the product spec as a measure of peak power output, not constant power. Another common source of confusion was to quote the volume of air a compressor could deliver at a lower pressure than the industry standard (thereby artificially inflating the stated power of the equipment).

So if you can’t rely absolutely on the stated horsepower of the machine, what can you rely on? Well, start with the standard measurement, which is SCFM (ie the volume – in cubic feet – of compressed air delivered in a minute, at sea level, 35% humidity and at 68°, compared to the discharge PSI. At least when you compare the SCFMs of two competing air compressors, you should be comparing like with like.

Even then, if you’re to guarantee being able to generate all the air you need, our advice is to overestimate your air requirements by 40%. That way, you’re certain not to find yourself with a brand new air compressor that’s unable to deliver during your peak demand periods.

If you need help ensuring that the decision you make is the right one, we’re here to help. Give us a call on 0114 243 2347 or contact us.

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Ask us to repair your air compressor equipment and we won’t charge you a callout fee, but we will run through some simple troubleshooting over the phone to ensure the problem isn’t something you can resolve yourself.

With all the tips below, if they don’t solve the problem, or if you don’t know how to carry out our suggested checks, give us a call on 0114 243 2347.

•  Air compressor won’t turn on

Has a safety cut out tripped? Check the overload relay and reset if necessary. Make sure the emergency stop is out.

•  Compressor is running but not producing any air

The air is supplied via an inlet valve controlled by a solenoid valve. Whilst you may be able to check whether the valves have power, you’ll probably need to call us to fix the problem.

•  Compressor is not getting up to pressure

Could be caused by a variety of problems including leaks somewhere in the system or problems with inlet filters. Before you call us, check that the level of demand isn’t outstripping the air compressor’s capacity. If it is, it will be new compressor equipment you need, not a repair.

•  Compressor keeps cutting out

Check that your air compressor has the recommended levels of ventilation to ensure it’s not overheating. Check the oil too, and top it up if necessary.

•  There’s water in your compressed air

It’s completely normal to have a little water coming out of your compressed air system as it’s a natural by-product of air compression. But if you check the condensate trap or the manual drain and there’s lots of water there, give us a call.

If the above suggestions haven’t solved the problem, or if your problem is not on this list, please call us on 0114 243 2347, or contact us.

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It’s not unusual for an air compressor to make a bit of noise, but you quickly notice the difference between business as usual and ‘something’s not quite right’. Odd noises don’t necessarily point to a major problem, but they are worth getting to the bottom of, not least because minor issues tend not to stay minor for very long.

My air compressor is:

 
Squealing briefly on start-up:
Don’t worry – this is quite normal.

Clanking:
Often a sign of a loose part, which means your compressor will need a swift service if it isn’t to result in a breakdown.

Hissing:
Can be a sign of a refrigerant leak.

Screaming:
Could be sign of extreme internal pressure. Switch the compressor off immediately and call us.

Clicking:
Often a sign of a faulty or failing thermostat.

Humming:
If it’s coming from the electric motor it could be a sign that the capacitor is on its way out. Call us for a repair.

Buzzing/Crackling:
If the noise is coming from around the fan motor it could be a sign of loose wiring, an arcing connection or a failing motor.

If your air compressor equipment is making a noise, don’t ignore it. Talk to use about servicing and repair that will keep your workforce safe, and production moving. Please call 0114 243 2347, or contact us.

What We Do

 
Servicing | Service Contracts | General On-Site Maintenance | Repairs / Remedial Work | Breakdowns | Pipework Installations | Electrical Installations & Work | Removal, Transportation & Reinstallations