10 Essential Maintenance Tips for Extending the Lifespan of Your Compressor

10 Essential Maintenance Tips for Extending the Lifespan of Your Compressor
ELGi authorized dealer based in Mumbai

Air compressors are a hefty investment which owners want to get the maximum benefit from. However, this is only possible by extending their lifespan through regular and proactive maintenance. Sudden breakdowns can be costly in terms of not just immediate repairs, but also loss of business and reputation. VEMC is the ELGi authorized dealer based in Mumbai

10 essential maintenance tips to extend the lifespan of your compressor

1. Replace filters

Air filters are used to prevent debris and particulates floating in the surroundings to get sucked into the air compressor. Over a long period of time, the cumulative load can become quite heavy. This can be problematic if you are operating in an industry like food processing and pharmaceuticals where high hygiene standards are necessary. Ensure air filters are replaced frequently.

2. Tighten loose bolts

Due to continuous vibration, your compressor bolts may get loose. Make sure you inspect and tighten them regularly to keep your air compressor in good working condition and avoid any sudden breakdowns.

3. Drain excessive moisture

Any moisture getting sucked into your compressor can cause rusting or microbial growth inside. This can damage the compressor and compromise the quality of your compressed air. Make sure you drain the excessive moisture regularly to avoid this.

4. Check oil levels

As all air compressor dealers in Mumbai will warn you, keeping the air compressor lubricated is a must. Check the oil levels once a day to ensure the moving parts are operating seamlessly and wear and tear is minimized.

5. Monitor temperature

Air compressors function best within a certain temperature range. If your compressor gets overheated, it can cause serious wear and tear. Some compressors come with an automatic shutdown feature on reaching certain temperature levels. Monitor temperature levels regularly and check if the automatic shutdown feature is working properly to avoid this.

6. Look for leaks

Any leaks in the hoses can cause a loss of pressure and make the compressor work harder. The compressor can become corroded or cracked due to leakage. Overall, it can cause wear and tear beyond normal levels.

7. Check air quality

Poor quality of air from the compressor can affect the standard of your operations. Check the air quality regularly to ensure airlines, filters, and other parts are functioning optimally.

8. Conduct repairs quickly

Having a lax approach towards minor repairs can harm the air compressor in the long run. Be proactive with your repairs and address them as soon as any issues arise. 

9. Troubleshoot

Take time to read the manual to know how your air compressor functions. This will enable you to troubleshoot whenever any issues arise to avoid things from getting out of hand.

10. Follow instructions

Do not assume that all compressors can be repaired in the same standardized way. If you face any trouble, follow the company’s own step-by-step guide.

You can get the most out of your air compressors by extending their lifespan if you maintain them. For more information on maintaining your compressors, call us on 022 43436655 or email us at marketing@vemc.co.in. VEMC is the leading Kirloskar pump dealer and ELGi compressor dealer in Mumbai.

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.

8 Ways To Improve The Efficiency Of Your Compressed Air System

Improve The Efficiency Of Your Compressed Air System

A number of factors can hold back your air compressor from performing optimally and giving you the best results at lower costs. Whether it is your compressed air filter or lubrication, everything must work seamlessly in tandem, enabling you to make the most of your compressor at limited energy inputs.

Here are 8 ways in which you can boost the efficiency of your Elgi air compressors and ensure they work for you.

Understand Lubrication

Like all other equipment in your facility, an air compressor consists of moving parts. To avoid wear and tear on these parts while they’re in action, lubrication is a must! However, both over and under-lubrication can create problems. Also, the quality of the lubricant must be chosen carefully to avoid damage to the machine. This is all the more important if you’re using your compressor in a sensitive line of work such as food processing or confectionery, as it can poison the consumables. Each system requires a specific type or level of lubrication and the safest way out is to go through the user manual and follow the instructions.

Know how Particulates Impact your System

Particulates can enter your Elgi compressor system, hamper its performance or even cause damage to the parts. All of this depends upon the atmosphere where an air compressor is being used and accordingly necessitates the use of a good quality compressed air filter, such as an Elgi air filter.

Prevent Compressor Contamination

Both moisture and particulate matter can be a source of contamination for air compressors. This can cause poor air quality of air being forced out from the compressor or damage to the internal parts of the compressor itself. To avoid this, regular inspection, the use of air dryers, or the right air filter for the compressor, is important.

Cooler Building Temperatures

Both increases and decreases in temperatures can cause the performance of an air compressor to plummet. This can be combated by regulating the temperature of your building using air conditioning, central heating, or natural ventilation.

Reusing the Energy you Create

Sustainable use of air compressors can be ensured by avoiding wastage and making the most of the energy released. Air compressors release a lot of heat as they function. So make sure you tap this heat and utilise it well for some or the other function, in your building.

Keep your System Clean

All mechanised equipment requires regular upkeep and maintenance to ensure optimum performance. Air compressors are no exception. Inspect and replace the compressed air filter frequently and clean the inner parts regularly to keep the system in its best shape.
Whether it is replacing your compressed air filter or scheduling an audit for your compressor system, we can keep a close watch on all your maintenance parameters. We are the leading Elgi air compressor dealers in the country, and pride ourselves on having a rich industry experience of 72 years. So get in touch with VEMC –– the most reliable Elgi compressor dealer in Mumbai out there, and book an audit at 022 43436655 or email us at marketing@vemc.co.in.

When To Add An Air Dryer To Your Compressed Air System

Air Dryer in Compressed Air System
Air Dryer

If you own an air compressor, you must have come across lots of suggestions online or otherwise, of adding an air dryer to it. This is because moisture in compressed air can be quite harmful to your machinery and some moisture-sensitive business operations as well. The degree of harm of course varies from one business operation to another. It can cause moulds or rust to develop over the metallic parts of your equipment (including the air compressor itself) and significantly reduce their working life and also affect their performance. Well, this is where an air dryer comes in!

An air dryer effectively saps the moisture from the compressed air, helps you prolong the life of your machinery, and also performs the tasks at hand perfectly well. In this blog, we take you through all that you need to know about air dryers in your compressed air system. 

What type of air dryer do you need?

Your choice of an air dryer for your compressor depends largely on the function you want it to perform and also your geographic location. Your Elgi compressor dealer in Mumbai will typically take you through the two types of air dryers that use these mechanisms: 

  • Desiccant air dryers: These are best suited for typically cold climes where the risks of freezing are quite high. These air dryers use desiccants such as silica gel or activated alumina which suck the moisture from the air as it passes through the compressor system. These can also be put to effective use in cold storage of pharmaceutical or food processing companies.
  • Refrigerated air dryers: In this type of air dryer, a refrigerant chills the air down to sub-zero temperatures. This freezes any moisture present in the air which is then removed before rewarming the air and pushing it through the piping to finally use it for the operation.

Selecting the right air dryer for your application

Moisture can cause serious damage to your equipment and in fact your air compressor system. But besides that, some business or industrial operations may require absolutely moisture-free operation and atmosphere. According to one estimate, moisture-related damages lead to the discarding of approximately 10% of all containerized goods. For instance, moisture can be a cause of serious losses in confectioneries, dry fruit, or wafer packaging operations. If you’re using a compressor in such facilities, therefore, you must ensure the complete removal of moisture from the compressed air.  Most air compressor dealers will recommend an Elgi air dryer –– a fantastic product that can come to your rescue when it comes to getting rid of unwanted moisture in your compressed air.
Make sure you’re purchasing an Elgi compressor or Elgi air dryer, only from authorised Elgi air compressor dealers who have both the product and the technical expertise for servicing it. VEMC is one highly acclaimed Elgi dealer that deals in both Elgi air dryers as well as Elgi air compressors and has a rich industry experience of over 72 years. If you need help finding the right compressed air dryer for your requirement, feel free to speak to our experts at 022 43436655 or email us at marketing@vemc.co.in.

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.

How to Use an Air Compressor: Things to Consider

How to Use an Air Compressor

A number of things need to be considered while using an air compressor for your operations. These include maintaining the right parameters like pressure, checking oil levels, having safety measures in place, etc. In this blog, we take you through all these aspects in detail.

Picking the right compressor for your needs

For domestic purposes, the most commonly used air compressor is the reciprocating piston type. This works by reducing the space to increase the pressure of the air inside the compressor. This is quite similar to the working of an internal combustion engine. 

For industrial purposes such as large refrigeration or pneumatic tools, rotary screw air compressors are mostly used. These work by compressing the air inside in a continuous sweeping motion, thus avoiding any pulsations that may occur in a reciprocating piston-type compressor. 

Getting started

  • Place your compressor in the right position. Ensure that the compressor is on an even and stable surface and the power source is always grounded. 
  • Turn the power on and allow your compressor to run for a minute. 
  • Set the psi as per your requirements. Adjust the pressure till you reach the recommended pressure for a particular tool. 
  • Connect the air hose and the tool you’re going to be working with. 

Oil and air intake

  • Check the level of oil in your compressor. Add oil by removing the cap and filling up to the mark if required.
  • Check the drain valve located at the bottom of the air tank. Make sure it is tightly closed.

Moisture and drainage

It is necessary to remove excess moisture from your air compressor at frequent intervals. This is usually done through the drain valve present at the bottom of the air tank. Wrench open the valve, allow the condensed moisture to flow out, and replace the valve. Always store the air compressor in a cabinet away from moisture.

Power

Make sure you turn off the compressor’s switch before you plug it into a three-pronged socket. As much as possible, avoid using extension cords if you’re unable to reach the spot of operations comfortably. Instead use an additional air hose and plug it into the first one. Extension cords can cause overheating of the air compressor. 

Meeting all safety regulations

  • Always use polycarbonate goggles and closed-toe shoes while operating the air compressor. 
  • Pull on the safety valve to test if it works.
  • Ensure you are only applying the right amount of pressure for a particular operation and as per the requirements of a particular tool. Try to maintain the pressure on a slightly lower side for safety.
  • Only operate the tool while there is air in the tank.

For more tips or information on how to best use your air compressor systems, feel free to get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised Elgi compressor dealer with an experience of over 72 years.

What is The Difference Between PSI and CFM in an Air Compressor?

If you’re looking for the right air compressor for your business, and are researching on the specifications of the product, you must have come across acronyms like PSI and CFM. These are necessary to tell you which size of air compressors are fit for your needs. Both these parameters are performance indicators of air compressors and other air-powered equipment. The main difference between PSI and CFM is that the former measures pressure and the volume of the latter measure. In this blog, we take you through a detailed understanding of both these metrics.

What is PSI?

PSI stands for pounds per square inch. Quite clearly it measures how many pounds of air occupies a square inch area. The greater the PSI value of a compressor, the greater pressure it is exerting and hence the more powerful it is considered to be. Quite simply, an air compressor with a PSI reading of 120 would indicate that it delivers 120 pounds of pressure per square inch. On an industrial compressor, the PSI value is typically displayed within the compressor system. As a convention ‘PSI’ is written in small letters. 

What is CFM?

CFM stands for cubic feet per minute. This indicates the volume or output rate of the air compressor in terms of cubic feet of air per minute. Simply put, it indicates how much air is being moved per minute. CFM is always measured at a particular PSI and increases proportionately along with the horsepower applied. Domestic compressors typically offer a volume of around 2 CFM while large industrial compressors that usually run at 200 HP, can deliver up to 1000 CFM of airflow. 

How are pressure and flow related in an air compressor?

To run an air compressor optimally, both volume and pressure must be sufficient. The principle isn’t very different from that of a garden pipe. When you squeeze the end of the pipe with your thumb, you are in effect reducing the space and creating less room for it to flow out. This will make the water shoot out farther. In air compressors, PSI and CFM relate to each other in a similar way. 

For the purpose of mathematical calculations, the relationship of pressure with volume in a compressed system can be demonstrated by Boyle’s law which states that:

P1 x V1 = P2 x V2

(P1 and V1 represent initial pressure and volume, and P2 and V2 represent final pressure and volume.)

The risks of over-pressurisation

Many times, users may over-pressurise the air compressors to ensure enough pressure is applied for a given task. This could pile up irrecoverable costs of energy losses since an increase in PSI value invariably increases the energy consumed. It can also reduce the lifespan of your equipment as the ‘artificial demand’ (another term for over-pressurisation) can cause unnecessary wear and tear.
For any questions regarding flow rates or accurate pressure levels for your air compressor systems, feel free to get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised dealer of Elgi air compressors with a rich industry experience of over 72 years.

4 Interesting Ways Compressed Air Is Used

Beyond the traditional applications, air compressors are used for, there are several unique ways in which compressor systems can be used. The amazing feats your air compressors are capable of are sure to leave you surprised! These are unconventional arenas, further away from the traditional applications such as in the manufacturing, pharmaceutical, and food and beverage industries. 

It can, in fact, help power some of the most ambitious projects of human beings. Looking beyond conventional uses can help you realise the true power of your air compressors

Let’s look at 4 such unconventional applications: 

1. Artificial Snow – If you think all sky-high hills are natural, think again. Organic, white, and fluffy snow is not as easy to procure. However, they can surely be created artificially. Compressors are an indispensable tool to achieve this. The huge machines that create lofty hills of artificial snow depend on water from compressed air at the right temperature and humidity. And voilà, you have snow on demand!

2. Projects by NASA – Air compressors also help power space shuttles at the International Space Station (ISS). Two of the most important applications of compressors are to launch space shuttles and help sustain human life in space. 

For example, the speed required by space shuttles to escape the Earth’s atmosphere is around 25,000 mph. This feat is achieved by compressors along with turbine engines. Without compressed air to increase pressure and deliver liquid hydrogen and liquid oxygen to the engines, they won’t be able to combust fuel effectively and provide adequate energy.

Also, human life in space is heavily dependent on compressors. Compressed gas, when introduced into space, and decompressed and mixed, can act as a precious source of oxygen. From a real-life example, when ISS was launched into space, compressors were used as the primary backup for oxygen. 

3. Roller Coasters – Not just scientific inventions; compressors find applicability in recreational activities as well. The air brakes, safety gates, special effects, and launch systems are all powered by compressors. This helps create an other-worldly experience for people and makes it safer for them. Compressed air in roller coasters also help them run on water and reduce the need for electricity. 

4. Trains – Can you imagine the speed at which freight and passenger trains run? It’s around 220 mph. However, the essential thing is not only to move at that speed, but also to stop when required. This is where air compressors come in. The brakes in these trains run on compressed air. Compressors provide the force which closes pads onto the discs and blocks the wheels, thus forcing the trains to stop. 

Air Compressors for your Industry

Compressor systems can be a powerful resource for any industry. It can help bring to life some of the biggest ideas of mankind. Whichever industry you are in, compressors can help power your operations. Vijay Engineering and Machinery Company (VEMC), an ISO 9001:2015 certified company, is a pioneer in the field of electromechanical engineering products, allied equipment, and services. With over 72 years as an ELGi air compressor dealer, we can guide you to best use compressors for your industry. Feel free to call us on +91 98199 07445 and we would be happy to assist you.

3 Must-Have Compressed Air System Accessories That Improve Performance

Have you ever observed your air compressor functioning closely? Their entire efficiency depends on receiving the right proportion of clean and dry air, at the right locations and at the right pressure. When your compressor system is not working properly, it means that at least one or two of its components are malfunctioning — perhaps a blocked filter, lack of an air dryer, or an unsuitable pressure regulator. 

It’s commonly said that your air compressor system is as powerful as its weakest component. Hence, it’s extremely important to ensure that your compressor has all the right accessories it needs to function properly. They not only help boost your energy efficiency, but also reduce frequent needs for maintenance. The ultimate benefit is the long life of your compressors. 

In this blog, we list out 3 of the most important accessories you need to keep your air compressors healthy and running: 

1. Compressed Air Regulator – Air compressors run on extensive amounts of energy, with requirements varying for different applications. So, when the energy input goes wrong, it can damage the components in the system. It also means wasted energy and ultimately, wasteful expenditure. 

Choosing the right pressure helps you zero in on the right energy requirement for your compressor. If your compressor runs at a higher pressure than is required, you may be wasting energy, while adding unnecessary pressure on the other parts such as hoses and fittings. This will lead to wear and tear and reduce the lifespan of your compressor. If a component is best suited to work at 100 psi and you operate it at 150 psi, it will not perform optimally.

Regulators help solve this problem by regulating pressure from the machine and aligning it with specific components based on different pressure requirements. 

2. High-performing Filter – Your compressor systems don’t necessarily have clean air inside them. They may contain several particles, aerosols, and vapours often found in the natural environment. 

A powerful filter can help remove contaminants from the compressed air and hence, it’s important to choose the right filter. For some applications, specialized oil-removing filters will make more sense; for others, dust and pre-filters may be apt. Before zeroing in on a filter, be sure of the requirements. 

Most choices usually boil down to coalescing filters, vapour removal filters, and dry particulate filters. 

3. Air Dryer – It’s natural for compressors to create lots of vapour while it is operating. This stagnant moisture can damage compressors and their parts. Especially in the case of metal or machinery, the presence of moisture leads to mould growth. This is not an ideal condition for any application, particularly in hospitality or healthcare. Blocked air pipes, stuck air cylinders, and rusted transmitters can also lead to increased maintenance and repair costs. 

Air dryers can help eliminate moisture before they reach the tip of the tool. Air dryers such as desiccant dryers use silica gel, activated alumina, or molecular sieves to de-vapourise air. You can choose from the desiccant and refrigerated dryers for your compressor systems. 

Getting the Right Parts

Your compressor system is heavily dependent on tools and accessories. Hence, the right tools are critical for compressors to function efficiently. Even if you are using a good air compressor, you may not get the desired performance if the quality of the parts is sub-par.

VEMC is a pioneer in the field of electromechanical engineering products, allied equipment, and services. You can order ELGi air compressors, air filters for compressors, and other accessories by calling us on +91 98199 07445. At VEMC, our technicians can guide you about the right parts, routine maintenance, and repairs, to help you get the most out of your compressor systems.