A metal processing company had a laser cutter installed in its manufacturing plant to produce accurately fashioned pieces from metal sheets. This machine requires compressed air that is dried to about 35Β° F for general use but requires a small amount of air to keep the beam path clean βthis avoids contaminating the expensive positioning […]
What is a lubricated compressor banana curve?
If you are carefully selecting your new compressors by looking at Compressed Air & Gas (CAGI) data sheets, you should be commended. Use of these sheets are a great way to compare compressor energy and flow characteristics between brands of compressors. In this way, you can choose the most efficient machine for your use and […]
Compressed air fail: A small compressor issue
A power utility had a 100-psi station service compressed air system that was used infrequently for maintenance. Two 50-hp water-cooled compressors were installed to maintain system pressure during the high flows, but these were overkill for normal times when the compressed air flow was only about 10 cfm. To reduce the number of starts and […]
Compressed air fail: desiccant dryer with too much purge
An industrial compressed air user was having a difficult time with their high pressure compressed air system. The compressed air demand required instrument quality air, so a heatless desiccant air dryer was installed. The dryer uses activated alumina within its chambers to strip off the moisture from the compressed air flow using an adsorption process […]
Compressed air fail: Auto mode was forgotten
One little button click can save thousands of dollars in wasted electrical and maintenance costs on air compressors. Recently, a compressed air auditor encountered the same problem in two different plants; operators had failed to select βAuto Modeβ on their compressors. Both units were 150-hp lubricated screw compressor installed in a system of multiple compressors. […]
Compressed air fail: Dew point bump
A compressed air auditor was hired to have a close look at the main compressed air system at a farm implement manufacturing plant. Data collection instruments were placed on the system to measure pressure, flow, and power. The auditor also placed a dewpoint meter at the discharge of the compressor room, after the main air […]
Compressed air fail: Hereβs a record you donβt want to break
One important item discussed in Compressed Air Challengeβs Fundamentals of Compressed Air Systems seminars is leakage. The most common waste category is compressed air. When studies are done looking at leakage rates compared to the total amount of compressed air produced, on average somewhere between 20% and 30% is found at manufacturing facilities (Fig. 1). […]
Material handling system features new vacuum technology
A new tooling system allows auto manufacturers to construct vacuum-end effector tools with minimal design time β to meet their exact needs for critical applications, such as sheet metal stamping, die-casting, injection molding, thermoforming, and glass handling. Made of hard-coat anodized aluminium, the Piab Modular Automation Tooling (PMAT) is lightweight and easy to assemble on-site […]
How can you reduce air leaks without turning a wrench?
What if you could reduce all your leaks without turning a wrench? Well, it is possible with good pressure control. And sometimes it is as easy as turning a knob. The principle is shown in the following orifice chart, Fig. 1. As the pressure to a leak reduces by 1 psi, the flow consumed by […]
Compressed air fail: Dead PFCs
One of many energy conservation measures available to industrial users is the use of pressure/flow control regulators. These are installed in systems to reduce the plant pressure while leaving the air compressors to operate within a wide pressure band, making them more efficient. A compressed air pressure/flow controller is a device used to regulate and […]
