Compressed Air Industry Trends to Watch in 2023

Compressed Air Industry Trends

As more and more companies become energy and cost-sensitive, compressed air will emerge as one of the most favored ways to power tasks in factories and homes. In this blog, we take you through some of the most significant compressed air trends that customers and air compressor dealers must watch in 2023.

Here are the trends in the compressed air industry to look out for in 2023

1. Demand for Compressed Air Equipment Remains High

Compressed air is often the 3rd or 4th most favored utility in the manufacturing industry. As per a market analysis report, the global air compressor market stood at $32.02 billion in 2020 and is expected to grow at a CAGR of 3.4% from 2021 to 2028. Although the growth was somewhat tempered by the pandemic which caused a general slowdown across sectors, the post-pandemic world is ever more focused on energy efficiency, reducing costs, and cutting CO2 emissions. With the growing standard of living especially in the Asia-Pacific region, air compressors will see plenty of demand due to the rising use of air conditioners.

2. Lead Times Remain Longer than Normal – Especially for Steel Parts

A number of factors can affect the lead times of spare parts such as demand, stockouts, shipping delays, inefficient inventory control, and unnecessary processes. An Elgi compressor with its sophisticated design is made up of a number of small and large components. 

When it comes to the spare parts of your air compressors, you might experience longer than normal lead times. This is because most industries are just reopening after the pandemic, and with a sudden spurt in demand, mills will be looking to complete orders of priority sectors ahead of manufacturers of air compressor parts. This being a classic demand-supply problem, might even affect the prices of the spare parts, causing a bit of a concern to customers as well as air compressor dealers.

3. Compressed Air Supply Chains and Prices Are Stabilising

Compressor dealers have witnessed a serious disruption in business due to the pandemic. The complex designs and assemblage of a number of parts sourced from different manufacturers could make logistics for a typical Elgi compressor dealer rather challenging. But as the pandemic ebbs away, the global economy is recovering fast, most Elgi air compressor distributors would expect the supply chains and prices to stabilize once again.

4. Industrial Internet of Things (IIoT) Applications Are Coming for Compressed Air

The Industrial Internet of Things (IIoT) will have massive implications for preventative maintenance, performance tracking, and energy efficiency. Air compressors communicating over the internet can share the condition of their parts such as belts and motors. The enormous amount of data produced as a result will be handy in designing energy-efficient and high-performing air compressors. Monitoring will become remote and convenient as parameters like flow, pressure, speed, etc. will be available on mobile devices. 

VEMC is one of the leading ELGi Air Compressor Dealers in Mumbai. For details or any queries on Elgi air compressors, feel free to contact our experts at 022 43436655 or email us at marketing@vemc.co.in. We at VEMC are way ahead of other air compressor dealers with a proven track record of excellence. As the most reliable Elgi dealer, we are committed to swift on-call service and top-class preventative maintenance.

Industrial Air Compressor Preventative Maintenance

Air Compressor Maintenance

Maintenance of equipment is necessary to ensure longevity and energy efficiency. This applies to air compressors that are used daily in an industrial setting. In this blog, we take you through some of the pressing issues with regard to the preventative maintenance of your industrial compressors.

Difference between preventative and standard air compressor maintenance

In an industrial setting, it is necessary to have an inspection regime in place to make sure your compressor and its allied equipment are functioning at the optimum level. This set of checklists or procedures is known as standard maintenance. 

Preventative maintenance on the other hand is all about finding and arresting mechanical issues before they spread and cause costly downtime. The schedule of preventative maintenance varies from component to component. While some may require daily inspections, others can be checked once or twice a year.

Benefits of preventative maintenance for industrial air compressors

  1. Avoids downtime: Downtime for any production facility can be costly for business and with preventative maintenance, this can be avoided to a great extent.
  2. Saves costs: Sudden breakdown of systems can cost more as compared to regular preventive checks.
  3. Ensures energy efficiency: Preventative maintenance brings to the surface any gaps or issues behind the sub-optimal level performance of the air compressor.
  4. Increases longevity: With regular check-ups, fine-tuning, and cleanups, an air compressor system can be kept in good health. This helps avoid fatal faults or wear and tear in the system and increases its life span.

Recommended preventative maintenance checks

  1. Oil filter: Oil must not be allowed to leave with the compressed air as it can corrupt the surface if the compressor is being used for spray painting. Oil filters must be checked weekly and replaced after every 4000-8000 hours of use. 
  1. Lubrication: Change the lubricant every 3 to 6 months to ensure the health of the compressor. Non-lubricated surfaces of the system could cause serious corrosion of moving parts.
  2. Air filter: Check, clean, and replace the air filter regularly. You do not want unclean air or air laden with particulates to come out of the compressor and hit a surface being spray-painted or cleaned with the compressor.
  3. Motor bearings: Make sure the bearings are sufficiently lubricated. Carry out regular inspections and check the bearings after every 4000 hours. Lack of lubrication can cause the bearings to get stuck in place.
  4. Intake vents: The air entering the vents can become dirty if the intake vents are lined with dirt, dust, and grime. The same air will then be released in compressed form.
  5. Belts: Belts must remain firm to ensure the proper functioning of the pulleys and connected parts. Replace the belts before they lose their tension or break down in the middle of a task.

Which maintenance checks should a technician perform

While some maintenance tasks can be performed in-house by your own team, for others, it is best you consult the compressor technicians. Some of these situations are

  • Replacement of motor
  • Relocation of heavy compressors
  • Safety shutdown instructions
  • In case of a mechanical breakdown

For operation and maintenance tasks of your air compressors by our skilled and qualified technicians, get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised Elgi air compressor dealer with an experience of over 72 years.

Top 5 Ways To Minimise Your Compressed Air Costs

Air compression if not done with proper checks, maintenance, and energy audits could turn out to be a fairly costly affair. To control costs of air compression effectively, you must follow a checklist of critical factors. While most of these factors fall under your regular maintenance procedures, some require your special attention. In this blog, we take you through the most important measures meant to control costs while you compress air at your facility.

  • Avoid unnecessary running: The biggest overhead cost associated with air compressors is the energy cost. There is one simple trick that you can use to tackle this upfront: turn it off! Air compressors at most facilities are used during the business hours and yet these are often found running until late evening. This wastes precious hours of electricity and adds to your energy bills.
  • Look for leakages: Leakages in the piping can cause loss of air pressure although the energy expended on compressing the air might remain the same. This means that you are using the same amount of energy but getting lesser work done. It is extremely important to look for leakages due to corrosion, pipe breakage, sludge, and dust particles in the piping regularly. Keeping the piping clean reduces the likelihood of leakages caused by corrosion.
  • Use the right pressure levels: Using the compressor at pressure levels beyond your requirement can cause wastage of energy. One reason for turning up the pressure could be compensating for the loss of pressure due to leakages, clogged filters, and other piping problems.
  • Use proper piping infrastructure: Using the right piping infrastructure that determines the direction and pattern of flow of compressed air is essential. A variety of factors play a role in this regard. Getting the compressed air to the focal point through a short pipe can optimise pressure and reduce energy use. Similarly, reducing the diameter of the pipe can help increase air pressure, work on the focal point effectively, and reduce energy consumption significantly.
  • Recover heat: The heat generated as part of the compression process can be used for a number of productive purposes. These include warming the rooms or producing hot water in washrooms. This could indirectly reduce the energy that would otherwise be consumed by geysers and radiators, especially in colder regions.
  • Ensure proper maintenance: By and large, proper maintenance helps reduce operational costs in more ways than one. In fact, preventive maintenance is less expensive than breakdown maintenance which could result in halting of operations and loss of business.

These insights can help keep a check on the energy, operations, and maintenance costs of compressing air at your facility. 

For further assistance on air compressors, feel free to contact us on +919819907445. We would be glad to assist you in finding the best match based on your requirements. As one of the leading ELGi air compressor dealers, VEMC provides end-to-end services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Oil-lubricated or oil-free air compressors – which one should you pick?

Amongst a diverse set of criteria that you need to keep in mind while choosing your air compressor, the type of lubrication is one of the most important factors. Should you choose an oil-lubricated or an oil-free air compressor for your business operations? Well, the choice largely depends upon the type of industry you are in, the operations you carry out, and the specific role your pump is expected to play in your facility. All these factors are decisive in choosing the lubrication type for your air compressor. But first, you must gain a deeper understanding of both types of air compressors, and then decide whether they suit your purpose. In this blog, we do just that.

Oil-lubricated air compressors

Oil plays a crucial role in these compressors on multiple fronts. Of course, it keeps the moving parts in good condition by reducing unwanted friction. But it also plays the crucial role of dissipating the extra heat generated in the system. Besides, it offers to seal and helps in noise reduction. As these compressors are also available in piston technology, their efficiency, robustness, and ability to work quietly make them effective for a variety of pneumatic tools and accessories. Oil-lubricated air compressors find use in manufacturing, construction, recycling, waste management, and quarrying.

Oil-free air compressors

These compressors do not use oil for lubrication. Instead, their cylinders are coated with a material like Polytetrafluoroethylene (PTFE) which allows the piston to slide in smoothly. Since no oil is involved, the quality of air from these compressors is the same as that which goes in. As such, these compressors find tremendous application in processes where the air must be devoid of moisture or oil vapour. Here is a list of areas that prefer oil-free air compressors:

  • Food & beverage processing
  • Pharmaceutical manufacturing
  • Operating ventilators, surgical machines, inhaled medication systems (only for breathing air certified machines), and other critical equipment in hospitals
  • Semiconductor and electronics manufacturing
  • Automotive spray painting
  • Textile manufacturing

The oil-lubricated air compressors are on average more durable, efficient, and less noisy. These are preferred any day over oil-free compressors if the quality of air is not a precondition. However, regular oil changing is an overhead that comes as part of the package and marginally increases their maintenance costs. On the other hand, oil-free compressors have the sharpest focus on air quality and also have a much lesser carbon footprint. Having the benefit of both these perspectives, you can now make a well-informed choice between the types of air compressors for your facility.

For assistance with deciding on the air compressor that suits your needs the best, please contact us on +919819907445. We would be delighted to help you find the best product or service based on your exact requirements. As one of the leading Elgi air compressor dealers, VEMC provides a comprehensive array of seamless products and services to our clients. A pioneer in electromechanical engineering products, allied equipment, and services in the field, we are also ISO 9001:2015 certified.

How To Calculate The Right CFM or Airflow For Air Compressors

CFM is the short form of Cubic Feet per Minute (cu ft/min) and as is evident, it has a volume and a time dimension to it. CFM is, in fact, a measurement of how fast air flows into or out of space. The higher the CFM, the higher is the pressure exerted by the tightly compressed air on a pneumatic tool.

Analogous to power, CFM reflects the compressor’s ability to perform work over a certain period of time. While there is no doubt that CFM is a very useful metric of your compressor’s performance, there is, however, a need to understand the concept and arrive at accurate calculations.

Let us first try to understand the relationship between CFM and PSI (Pounds per Square Inch). While the two may seem conceptually alike, they have fairly distinct implications. CFM is the rate of flow of compressed air through a given space. It has a time dimension and is, therefore, a more dynamic metric. On the other hand, PSI is more static and is basically a measure of the pressure created by the compressed air per unit area. CFM is the driver behind PSI, which in turn reflects the Force that a compressor can exert and the amount of work it can get done. Both CFM and PSI determine whether an air compressor can meet your workload demands as each piece of equipment has its own airflow requirement.

There are a number of websites and online calculators that offer a simple and quick calculation of CFM. All you need to do is to enter the variables and within a split second, you arrive at your CFM. However, to gain a deep conceptual understanding of CFM, it is always advisable to do some good old math and arrive at the results through a formula. So, here we go:

CFM = Tank Volume in Cubic Feet x Standard Pressure (ATM) during a Cycle x Cranks per Minute

How to calculate Standard Pressure and Cranks per Minute?

Standard pressure must always be converted to PSI. Remember, 1 ATM = 14.7 PSI

Let’s say, your tank volume is 18 Cu. Ft, Standard pressure is 2 PSI and Cranks per Minute is 1.5.

By simple multiplication of the above-given variables, we get:

18 x 2 x 1.5 = 54 CFM

Another very easy method of calculating CFM is the airflow meter. This gives us the pressure coming out of a fitting and can be installed on individual pieces of equipment or complete systems to provide an instant reading.

For assistance to decide on the air compressor that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of the leading Elgi air compressor dealers and distributors, VEMC provides seamless services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Compressed Air – The Fourth Utility Of The Modern World

If water, electricity and gas form the trio of essential utilities of the modern world, compressed air has a strong claim to be the fourth one. Air is one of the most ubiquitous resources of nature. When it comes to utilizing it as a source of energy, however, you have to compress and direct it with precision. Compressed air can drive wide-ranging activities and find use in a number of sectors. In this blog, we take you through the importance of this powerful source of energy across the economy.

Manufacturing:

Compressed air finds utility in a number of activities in the manufacturing sector. It powers the actuators, conveyor belts, sprayers and clamping equipment. It also supports casting processes, offers optimal product finishes and helps clean the final products impeccably. 

Construction:

Another sector that requires some heavy lifting and muscle power is construction. Compressed air is used to power pneumatic tools like buffing equipment, nailing, stapling and riveting guns, grinders, drillers, jackhammers and sanders. Lowering and raising heavy loads or demolishing structures also make use of compressed air. Tunnel-digging is another area where compressed air does wonder. They are used for road digging, cutting and cleaning. They also keep the tarmac, debris and other hard surfaces debris-free. 

Agriculture:

Pruning, harvesting, crop fertilising, seed sprinkling and spraying are some of the activities that compressed air helps with, in the agricultural sector. Air compressors power the tractors, sprayers, conveyors and pneumatic fruit pickers. They also facilitate the operation of hydraulic pumps.

Healthcare:

Compressed air is used for administering anaesthesia, power ventilators and other surgical machines in operation theatres. Compressed air is always free of contaminants, pollutants and other particulate matter, making it extremely useful to maintain an allergy and infection-free healthcare facility. Compressed air is also used to inflate emergency mattresses for patients.

Automotive:

In this sector, air compressors find great use in engine construction, assembling car bodies and giving finishing touches to the cars. Intricate components are put in place using compressed air-based pneumatic tools. Plasma cutting, welding and inflating tyres also use compressed air. Finally, the air compressors are used to clean the car and paint it using dry and oil-free compressed air to prevent bubbles or splattering to form on the surface.

The above-given list is not exhaustive and air compressors are used in multiple other areas of the economy. In the future, as the efficiency, precision and power of the pneumatic instruments is improved, air compressors are expected to find the greater application and have an increasingly enlarged role to play.

For assistance to decide on the air compressor that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of the leading Elgi air compressor dealers in Mumbai, VEMC provides seamless services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Working of ELGI Air Compressor

How ELGI air compressor works?

An air compressor is a device designed to pump compressed air. It is used to ensure the circulation of cooling refrigerant in a closed circuit, and the pumping of pressure into various containers. This equipment is widely used in medicine, industry, and household. Its presence allows you to perform a wide range of actions.

The principle of operation of the ELGI air compressor can be described as follows.

  • When the engine starts, the crankshaft begins to rotate, transmitting reciprocating movements through the connecting rod to the piston.
  • The piston, moving downward, creates a vacuum in the cylinder under the influence of which the inlet valve opens. Due to the difference in air pressure, it begins to be sucked into the cylinder. But before it enters the compression chamber, air passes through the filter.
  • Further, the piston starts to move up. In this case, both valves are in a closed state. At the time of compression, pressure begins to increase in the cylinder, and when it reaches a certain level, the exhaust valve opens.
  • After opening the exhaust valve, compressed air is directed to the receiver.
  • When a certain pressure has entered in the receiver, a pressure switch is activated, and air compression is suspended.
  • When the pressure in the receiver decreases to the set values, the pressure switch starts the engine again.

How to choose an industrial air compressor?

To select the right compressor, first of all, you need to determine how often it will be used, depending on your needs for compressed air.

You are also required to determine if you need a portable compressor or whether it will be used indoors. In this case, it is necessary to ensure good ventilation of the compressor to make sure that it has optimal cooling.

Also, consider the continuous running time of the compressor. Manufacturers usually indicate the duty cycle on these elements. This duty cycle allows you to determine the duration of the compressor for one hour. 

Purpose and principle of operation

What is an air compressor? This is a device designed to compress air and pump them to the required place. How does it work? The principle of operation of the ELGI compressor is quite simple; atmospheric air enters the mechanism that performs its compression. For this, different methods can be used. The mechanism that compresses the air determines the device and the principles of operation of the compressor. For the effective operation of the equipment, it must be connected to the electric network and the air network, through which compressed air will be transmitted. 

Common problems of air compressor

Unit overheating

Usually, the unit may overheat when operating in intensive mode or at an increased ambient temperature in the room. If the unit still overheats under standard operating conditions and normal room temperatures, then a clogged air filter may be the reason behind the malfunction. It should be removed and washed, then dry it properly.

Knock on the cylinder

It is caused by a breakdown or wear of the piston rings due to carbon deposits. Usually, it appears if you use low-quality oil. Knocking-in the cylinder can also be caused by wear on the connecting rod. These parts should be replaced with new ones. When the cylinder and piston are worn, repair of the air compressor consists of boring the cylinder and replacing the piston.

ELGI air compressors are very essential since they require small maintenance. Apart from that, they are highly reliable and huge. This is the reason why they are good for industrial applications. Ensure that you look for reputable dealers in the same product. You may opt for the ELGI air compressor dealers in Mumbaiwho are reliable and have the best products.