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.

Applications of Screw Air Compressor in the Paper and Textile Industry

Air compressors are used widely across all industries. They serve a variety of purposes in the least possible time. The capacity and capabilities of a screw air compressor depend upon its usage and applications. Screw compressors are usually large due to their capacity to receive the air. The larger the size of the tank of the compressor the greater is its capacity. The engine size of a screw air compressor is larger than a normal compressor to successfully carry out various functions. The power consumption of a reciprocating air compressor is large. It requires a considerable amount of energy to function and serve various purposes.

Following are some of the applications of screw air compressor in the paper and textile industry:

  1. Spinning: One of the major functions of an Elgi air compressor is spinning. A screw air compressor is used in paper and textile industries for spinning. A screw air compressor also helps in a ring, air-jet spinning as well as open too. A screw air compressor makes it easy to spin the textile and achieve the desired outcome.
  2. Texturing: In the paper and textile industry, one of the major concerns is the texture of the final product. A screw compressor is used at various stages in a factory to get the perfect texture of the product. In this process, yarn is intermingled with the help of a nozzle and the jet. The pressure generated during this process helps one to achieve the texture required.
  3. Air-jet weaving: the modern technique of air-jet weaving is popular for its swift results and perfect alignment. A screw air compressor is used to blow a yarn with weft transportation. This is one of the most crucial stages; it requires technical expertise and complete know-how to ensure the yarn is blown optimally while using the right combination of machinery and industrial equipment.
  4. Pneumatic conveying: A screw air compressor is used for pneumatic transport and allied works. The screw air compressor is extensively used for fabric and PET chips. They ensure flawless performance and provide optimum results in the least possible time. 
  5. Man-made fibre production: A reciprocating air compressor is used for the production of partially oriented yarn (POY) and fully oriented yarn (FOY). The air compressor enables faster production of quality yarns. However, the size of the screw compressor depends upon its application and production capacity too.
  6. Garmenting process: There are several processes involved in the production of the garment. Some of them include printing, stitching, marking, cutting, laying, and much more. An air compressor can be highly useful in streamlining the process and scheduling the production too. A screw compressor optimizes the process of production. Therefore, it is widely used in the textile industry. 
  7. Dyeing textiles: Screw air compressor helps one to transfer a yarn to spool or cone for dyeing and other purposes. Compressed air is used for dyeing purposes and dyes the fabric/textile with the planned colour. 
  8. Packaging: The screw air compressor is used to wind the yarn and package them as per one’s needs. Packaging plays a very important role whether it is textiles or paper. The wrap beams and air compressors are used together for packaging purposes and wrapping too. Compressed air is also used for sizing the paper and textile products.
  9. Combing: Combing is the process of removing impurities and short fibres with the help of rollers and brushes. The screw air compressor can make this difficult task much easier and organized. One can get a pure version of output with minimal efforts with the help of the screw compressor.
  10. Treating wastewater: One of the most important parts of production is managing wastewater and wastage. Whether it is the textile industry or paper, it is imperative to efficiently plan wastewater treatment to get rid of the impurities optimally. The screw air compressor can facilitate wastewater treatment with utmost efficacy.