Air Compressor Maintenance Costs
We sell and lease some of the world’s best air compressors from the Atlas Copco range. We also service compressors from every major manufacturer. What they all have in common is a need for regular servicing and maintenance.
However good the air compressor may be, servicing is essential. Sooner or later, you will need to replace consumables like filters, address wear and tear on parts, or even deal with the consequences of a mishap or accident that damages your compressor.
Choosing the right servicing option is just as important as selecting the right air compressor. Getting it right minimises downtime, extends the life of your compressor, and gives you the lowest lifetime cost.
What air compressor maintenance costs cover
Your servicing costs will cover the expenses associated with maintaining your air compressor at optimal performance levels.
Consumables
All compressors require periodic replacement of consumables, such as oil or filters.
Frequency will be affected by operational factors as well as options used. Atlas Copco has primarily transitioned to synthetic oil, which only requires changing every two years or after 8,000 hours of operation; older machines using mineral oil will necessitate more frequent changes.
Repairs
Your servicing plan may also include incidental repairs, such as those resulting from component failure or accidental damage.
Including these unpredictable maintenance needs in a servicing contract can reduce downtime.
Labour costs
Perhaps the most valuable element of a servicing contract is giving you the time and expertise of an experienced engineer.
Compressed air systems can be complex, so using skilled professionals is essential to ensure work is conducted correctly. Search Air’s team has hundreds of years of collective experience in compressed air.
Factors Influencing Maintenance Costs
The versatility of air compressors means that every installation will have unique features, but a few broad factors determine overall costs.
- Air compressor type: generally, piston compressors are the most cost-effective type to maintain, with rotary screw compressors being more expensive. Oil-free compressors tend to have lower consumable costs.
- Usage patterns and operational intensity: infrequently used compressors may only need to meet the manufacturer’s recommended minimum service guidelines. Compressors that operate continuously will require more frequent servicing. Likewise, operating compressors close to their maximum will tend to increase the need for maintenance.
- Environmental factors: the environment is perhaps the most significant determinant of maintenance costs. Polluted environments, for example, may require more filters, which in turn means your compressor has to work harder, both factors that will increase your maintenance needs.
How often is servicing needed?
Your manufacturer’s recommendations should be considered a bare minimum; most users will require more frequent servicing.
Atlas Copco’s high build quality typically results in the lowest recommended frequency, usually every 4,000 or 8,000 hours of operation, depending on the model, with an annual service recommended if those hours are not exceeded.
At the other end of the scale are HPC and Ingersoll Rand, who suggest 2,000-hour intervals, with BOGE taking a middle ground approach of 3,000 hours. However, most manufacturers are shifting towards longer intervals to match Atlas Copco.
We are always careful to avoid over-servicing; however, for most users, other factors will necessitate more frequent servicing. A good servicing plan achieves the balance that optimises your compressed air production.
Air Compressor Maintenance Costs
The dangers of neglecting maintenance
Like any plant or equipment you operate, proper maintenance is an investment.
Good maintenance maintains performance and efficiency. Addressing issues like air leaks, for example, can have a significant impact on both energy costs and productivity.
In the long term, good, proactive maintenance reduces wear and tear, as well as damage, to your compressor. This will help avoid equipment failures, costly downtime, and extend the lifespan of your compressor, all reducing the lifetime cost of your compressed air system and helping you maintain profits.
You also have a legal duty to ensure your equipment is safe. Under UK law, you are required to service your compressor at least once a year and provide a safe working environment for your staff. A well-maintained compressor is safe, but even a small compressor that has not been looked after poses a risk to those around it.
How to reduce maintenance costs
Just because you should not skimp on maintenance does not mean you cannot reduce maintenance costs. Some ways you can cut costs include:
- Stick to your manufacturer’s maintenance schedule. Some service providers cut corners by offering oil or filter changes but skipping part replacements. This might reduce the servicing bill, but at the cost of far more expensive repair bills in the future.
- Use genuine original equipment manufacturers parts and consumables. It can be tempting to opt for cheaper parts you can find online, but it is a gamble when it comes to demanding air compressors. Using manufacturer parts ensures that they have been designed and tested specifically for their equipment.
- Train your staff. Well-trained staff make an enormous difference to a compressor; ensuring they know how to use the compressor correctly will also prolong its life. They can also undertake simple maintenance tasks, allowing service engineers to focus on the more challenging jobs. Search Air can offer on site training for your staff.
Choosing the right service plan
We always recommend getting a good service plan for your compressor. While pay-as-you-go can be an option, it is inherently reactive and can lead to delays when urgent work needs to be completed.
Servicing options provide consistency for your compressor and your budget. We offer all-inclusive plans with monthly, quarterly, or annual payment options. You get the certainty of knowing that your needs are covered with a fixed fee, especially as our plans can lock in the price for as long as five years.
The plan that is right for you will depend on your system and how you use it. Just contact us, and we can take you through our options. Alternatively, we can visit to inspect your system and provide a free quote, breaking down the options and our recommendations.
Search Air work with hundreds of businesses that trust us to keep their air compressors in top condition. Contact us today to learn more.