Air compressors are great at powering tools and processes, but only when you get the right compressor size. Too small, and you create problems, straining the compressor, causing pressure drops and malfunctions. Too big, and you may power your system easily, but at the cost of unnecessary energy use.

Unfortunately, getting the right air compressor size sometimes seems more arcane magic than an operational decision. But once you understand the basic concepts, deciding the compressor size you need becomes much more straightforward.

Some compressed air basics

Determining the best size of air compressor means you need to understand a few different, but related, measures.

Airflow

The airflow is the volume of air that a compressor can deliver. This is usually measured in cubic feet per minute (CFM), but may also be in metric equivalents like litres per second (l/s) or cubic metres an hour (m³/h).

This is, simply, the volume of air the compressor can generate in the timeframe. An air tool will be rated by its requirement, air drills, for example, can require between 3 and 8 CFM depending on size.

Pressure requirements

This is the air pressure the compressor can generate. Typically measured in pounds per square inch (PSI), most compressors and tools will also feature the metric pressure measurement ‘bar’, which is equivalent to around 1 kg of pressure per square centimetre.

Again, tools will have a pressure requirement. The air drill, for example, may need around 70-90 PSI. It’s important to note that although air volume and pressure are related, compressors are rated for specific volumes and pressures. You must ensure your compressor’s rating meets airflow and pressure requirements.

Duty cycles

A final factor in some compressors is the duty cycle. This is how much time the compressor can operate in a given cycle. It is expressed as a percentage.

Cycles are often 10 minutes. A duty cycle of 75%, for example, means the compressor would operate for seven-and-a-half minutes before resting for two-and-a-half minutes.

Air Compressor Sizing Guide

Using these to determine compressor size

When you understand each of these factors, you can use them to calculate the size of compressor you will need.

Establishing your peak demand

Your compressor must be capable of supporting your peak demand, the time when your operations will need the most compressed air. It’s unlikely you will be using all your tools at once, so calculate the highest total demand your operations make.

Factor in a buffer

Operating a compressor at its maximum rating is not recommended. Instead, you should factor in a buffer. Factors like your system efficiency and even expansion plans will determine the best size, but around 10-30% is a typical amount to allow. For example, if your peak demand is 10 CFM, you would want a compressor between 11 and 13 CFM.

Allow for a duty cycle

If your compressor isn’t rated for continuous use, you must allow for the duty cycle. If, say, you needed 12 CFM from a compressor with a duty cycle of 75%, the compressor would need to generate at least 16 CFM (12 CFM * 75%), so it could store air to use during rest periods.

Common mistakes

The easiest way to get it right is to have professional advice. Search Air has been designing, installing, and servicing compressed air systems since the 1950s, and can use our knowledge and experience to determine the right size for you, and help you avoid the common mistakes businesses can make.

Be careful with peak demand

Determining the correct peak demand is easy to get wrong. Make sure you have included everything. Getting it too low can result in pressure drops, leaving your tools underpowered and your productivity falling.

Think about the future

Don’t forget to factor in your business’s growth. Compressors have a long operational life, so even if your growth plans are a few years away, getting a larger compressor, or better still, a variable speed compressor that responds to demand, might be a better long-term choice.

Choose the right type of compressor

Size is important, but capacity is just one part of your choice. You also need the right type of compressor. You might have to choose an oil-free compressor to meet purity standards, or consider a variable speed drive rotary screw compressor to help manage energy costs if you have fluctuations in demand. Capacity is just one part of your choice.

Some typical installations

We constantly strive to design the best solution for everyone, but here are some example solutions to illustrate the choices.

The small workshop

Using a few pneumatic tools as needed, a smaller piston compressor like an Atlas Copco LE  series compressor provides the power and flexibility needed with between 3 and 16 CFM.

The industrial user

When operating several tools intensively and for longer durations, a larger unit will need a higher CFM, such as the Atlas Copco G and GA series. Rotary screw compressors, available in both oil-lubricated and oil-free versions, can offer from 50 to over 1,000 CFM, offering plenty of fluid power, and room for growth.

Construction work

Although using tools intermittently, the compressor needs to be both portable – moving to the work – and offer a high PSI for tools. An ideal compressor might be from the Atlas Copco XAS range, compact and easily portable, they all produce over 100 PSI.

The Search Air difference

With so many factors to consider, choosing the right air compressor for your needs might seem overwhelming. But we are here to help.

We have worked with businesses from single-person workshops to huge industrial manufacturers, establishing their air compressor needs, then installing a compressed air system that works and grows with their business.

We are trusted Atlas Copco partners, and can install anything from their extensive and award-winning range. Every customer is offered a personalised recommendation created with your needs and budget in mind.

Our partnership continues even after a compressor is installed. Search Air offers a comprehensive range of servicing options, from occasional maintenance to comprehensive 24/7 call-out options, that can keep your compressor in optimal condition, whatever its manufacturer.

Search Air is here to help with every step of your compressed air journey. If you are starting to think about your needs or want help with an aging compressed air system, call us today and find out why thousands of businesses trust us with their air compressors.

There are many factors to consider when choosing an air compressor. The choice between oil-free and oil-lubricated is one of the most important.

Your decision will impact things like cost, maintenance needs, and the uses to which you put your compressed air. While air purity is usually the chief consideration – oil-free compressors are the only way to prevent oil contamination – those other factors may well affect your decision.

The role of oil in air compressors

All air compressors work by reducing the volume of a mass of air, with different types of compressors using different techniques. Piston, or reciprocating, compressors work in a similar way to an engine, compressing air in pistons. Centrifugal compressors use the velocity of air, spinning it to create pressure. Rotary screw compressors, the type most often available as oil-free compressors, use interlinking screws to continuously push air into a smaller volume.

Each has different moving parts, and, like any machinery, oil is typically used as a lubricant. When used in a compressor, oil performs familiar functions:

• It lubricates. Oil lubrication helps keep moving parts moving freely, reducing friction and improving efficiency.
• It cools. Oil distributes and removes heat from the compressor.
• It seals. Oil fills the small gaps between moving parts, minimising the air loss that would lower pressure.

However, oil-free compressors remove all oil from the compression process, allowing them to generate Class 0, oil-free, compressed air.

The benefits of oil-lubricated air compressors

Able to use oil with every moving part, an oil-lubricated air compressor can take advantage of the functions oil fulfils.

• They can be more efficient, benefiting from reduced friction and better cooling.
• They have longer lifespans and are protected by the oil, reducing wear and tear.
• They can be better suited to heavy-duty tasks and prolonged operation, with reduced heat build-up.

The benefits of oil-free air compressors

Although oil-lubricated compressors have advantages, oil-free compressors have features that can make them more attractive.

• They are lower maintenance, usually having fewer moving parts, so less needs to be maintained.
• They tend to be smaller compressors. The simpler design can reduce overall size, making them attractive if space constraints are an issue.
• They are the only way to guarantee oil-free air. If your processes demand clean air, for example in food production or for breathing, going oil-free is the only way to achieve that.

Oil Vs Oil Free Air Compressors

Oil-free v oil-lubricated

Air purity

Compressed air quality is the most notable difference between the two. An oil-free compression chamber results in oil-free air. An oil-lubricated compressor, even with an oil filter, will have some air contamination.

Cost and expenses

Oil-free compressors, as a result of their specialised design, tend to be more expensive initially. However, they can offer some savings on maintenance costs.

Operational lifespan

Oil-lubricated compressors, because of the reduced friction and wear and tear, tend to have a longer life span. However, improvements in oil-free compressor design have greatly reduced and, in some cases, eliminated the gap.

Workplace impact

Oil-free compressors tend to be smaller, which can make them suitable for more space-constrained operations. However, this needs to be balanced against the increased noise and heat they generate without oil to disperse heat and absorb sound.

Compressed air applications

Aside from purity considerations, situations where the compressor is in continuous operation, or has to produce significant volumes of compressed air tend to be better suited to oil-lubricated compressors.

Choosing the right compressor

For most users, the choice is straightforward, but the key factors will be air purity, maintenance issues, risk and cost.

Air purity

Oil-free compressors are usually chosen because of the need for very high air quality. Applications like food production and processing, or pharmaceutical or medical uses cannot tolerate any risk of oil contamination.

For all other uses, an oil-lubricated compressor, with suitable filters can often achieve suitable purity levels.

Maintenance

Our engineers will always aim to minimise disruption during maintenance and servicing visits, but some disturbance will be inevitable.

If keeping the disruption and downtime from servicing to an absolute minimum is critical then an oil-free compressor helps you do that.

Budget issues

We know that every business has different budgeting needs and preferences.

Oil-free compressors come with a higher initial cost, but ongoing costs are lower. In some circumstances, an oil free compressor may be your best option.

Getting the right type of compressor

Search Air is more than happy to help you find the compressor that’s right for your unique needs. Just contact us, and we can help you balance your needs for compressed air, the location of your compressor, and even estimate your ongoing costs so you can be confident you’ve made the right decision.

FAQ

Which compressor is most cost-effective in the long run?

This will depend on your use case. Although oil-lubricated compressors tend to be more cost-effective over their lifespan, factors like use patterns, maintenance, and energy-efficiency affect this. We can help you estimate running costs as part of our design process.

Are oil-free compressors suitable for continuous heavy-duty tasks?

Most oil-free compressors are less well-suited for continuous operation and heavy-duty tasks. However, more advanced oil-free models can also manage these, using techniques such as water cooling to manage heat, or oil-free centrifugal compressors, which can generate large volumes of compressed air.

How often does oil need changing in lubricated compressors?

This varies from compressor to compressor, and you should always check your manufacturer’s documentation. As a general rule, it should be changed at least once a year, but your usage will affect that. Our servicing plans include filter and oil changes at appropriate intervals based on use, keeping your compressor running optimally.

If your compressed air solution is integral to your business’s daily operations, you simply cannot afford to overlook maintenance. Like all industrial equipment, air compressors are subject to wear and tear, and moisture is among the main culprits behind corrosion, rust, and toxins. Fortunately, an expertly installed Atlas Copco compressed air dryer can eliminate virtually all moisture from your compressed air.

Some compressor models come equipped with aftercoolers capable of removing up to 70% of the moisture from compressed air. However, you may require an additional air dryer in a sensitive or humid environment or an industry such as pharmaceutical, oil and gas, chemical engineering, or food.

At Search Air, we have set the bar high for the compressed air industry for over 78 years. That is why we were named Atlas Copco’s Compressor Distributor of the Year as recently as 2022. With a professionally fitted air dryer, you could extend the lifespan of your valuable equipment, guarantee high-quality and precise end products, eliminate environmental hazards, and much more.

Below, we will explain the benefits and inner workings of compressor dryers in detail but do not hesitate to give us a call for specific advice based on your unique needs.

Why Are Air Compressor Dryers Necessary?

The air we breathe, atmospheric air, contains trace amounts of water vapour. As the air pressurises rapidly, condensation droplets can form inside your compressed air system. This can lead to energy inefficiencies and degrade your system and all its connected equipment.

Air temperature directly impacts its moisture content, with hotter air containing more moisture. For example, a 7-bar compressor operating in a humid setting with temperatures of 20 degrees Celsius releases upwards of ten litres of water per hour.

Like all industrial equipment, air compressors are subject to wear and tear, and moisture in compressed air is among the main culprits behind corrosion, rust, and toxins.

How Do Air Dryers Work?

Essentially, a dryer separates moisture from the compressed air inside your solution. Dryers achieve this goal through refrigeration, absorption, diffusion, or filtration, depending on the type and configuration. The two main types of dryers in most UK workplaces are refrigerant and desiccant, but other types also include membrane and deliquescent.

What Are Air Compressor Dryers

Refrigerant Air Dryers

Refrigerant dryers are the most common type in industrial settings. These solutions remove moisture from the air using heat exchangers, which cool the compressed air and channel the resulting condensation into a drain. Refrigerant air dryers can be cycling or non-cycling, with cycling being the eco-friendliest solution and non-cycling having lower installation costs.

These dryers work particularly well with rotary screw compressors and are an economical option ideal for a variety of industrial settings.

Desiccant Dryers

Desiccant dryers are preferred in environments where moisture-free air is necessary, with no margin for error. These advanced solutions can achieve a pressure dew point as low as -70 degrees Celsius by adsorbing water from the air using an adsorbent material such as activated alumina.

Much more effective than refrigerant alternatives, desiccant dryers are suitable for industries such as medical and dental, electronics, food and drinks, pharmaceuticals, and painting. While they are more expensive to purchase and install than their refrigerant counterparts, their higher energy efficiency could reduce operating costs.

Other Types of Air Dryers

Other popular dryers include membrane dryers, which depress the dew point and dehumidify the air as it enters the compressor system, and deliquescent dryers, which use a pressure chamber containing salt tablets to absorb vapour. While these electric-free methods are eco-friendly, they are not as effective as desiccant or refrigerant dryers in terms of dew point performance and moisture removal.

In most industrial settings, where extremely low dew points are not required, refrigerant dryers are often the most cost-effective and practical option. However, every business’s needs differ. We are only a phone call away if you want to discuss your unique needs and future practicalities with an expert.

Benefits of Using Air Compressor Dryers

Moisture is inevitable when it comes to compressed air systems. It can, however, cause serious harm to your system and equipment if left unchecked. Fortunately, air dryers can effectively eliminate moisture from your compressed air, delivering benefits such as:

Prevent Freezing

In some industrial settings, vapour contained within compressed air can condense and freeze, jamming and wearing your solution’s internal moving components in the process.

Eliminate Contamination

Contaminated compressed air poses a serious risk to product quality if you operate in an industry such as food and drink or pharmaceuticals. Similarly, high moisture levels in compressed air can cause damage when sanding and blasting. A dryer can virtually eliminate these risks.

Contaminated compressed air poses a serious risk to product quality if you operate in an industry such as food and drink or pharmaceuticals. Similarly, high moisture levels in compressed air can cause damage when sanding and blasting. That’s why regular compressor air quality testing is so important. A dryer can virtually eliminate these risks.

Minimise Bacterial Growth

Bacteria and other harmful microorganisms are often found in the water vapour contained in air, which can build up in your system as it compresses. A dryer ensures that your compressed air remains toxin-free.

Prevents Corrosion

An air dryer can prevent moisture in compressed air from corroding internal components such as drums, pipes, vessels, and tanks, often made from steel.

Enhance Operational Efficiency

Even low moisture levels in compressed air can reduce the efficiency of your compressed air system and all the equipment it powers. This loss in efficiency is compounded by damage to your compressor’s internal components. Air dryers protect your equipment while enhancing operational efficiency and minimising downtime.

Air Dryer Support in Wakefield, South Yorkshire & Barnsley

At Search Air, we provide expert advice, installation, and servicing of compressed air dryers for businesses across Wakefield, South Yorkshire, and Barnsley. Whether you need a new drying solution or regular maintenance to protect your system from moisture damage, our team is here to help. Get in touch to keep your compressed air clean, dry, and efficient.

Discuss Your Dryer Needs with Our Experts

The best dryer for your compressor depends on your industry, environment, needs, and goals. If you want to discuss those with a seasoned expert, you have come to the right place. At Search Air, we have remained at the top of our game for the better part of eight decades, as you can see by perusing our reviews and industry accolades. Contact us today for more information on the latest range of dryers and how they can elevate your business.

Many compressed air systems in high-pressure industrial environments use oil to lubricate moving parts and reduce wear and tear. By choosing the right oil for your specific compressor, you can extend the lifespan of your equipment while ensuring smooth operation. However, accidentally or unwittingly using an unsuitable oil might do the opposite, potentially damaging your valuable equipment.

In this guide, we explain the different types of oil for air compressors and their practical uses and benefits. We will also discuss some of the most common oil-related mistakes and useful upkeep tips.

At Search Air, we have been an industry-leading supplier and installer of innovative compressed air systems for over 78 years, offering everything from air compressor servicing to expert advice on maintenance and performance. 

You can feel confident that we know a thing or two about keeping air compressors in pristine condition for a broad range of industries. If you need specific advice based on your unique needs and requirements, do not hesitate to give one of our experts a call.

Understanding Air Compressor Oils

Air compressors contain a lot of moving parts that generate heat and friction. A highly specialised lubricant, air compressor oil, is required to lubricate those moving parts and protect your system against wear and tear. In addition to lubrication, compressor oils perform a range of important tasks:

Heat Absorption

Compressor oil is highly effective at absorbing excess heat produced during the compression process, which helps to protect your system against overheating.

Anti-Foaming

Most oils contain anti-foaming agents that can extend the lifespan of your compressor by removing the foam that develops as air bubbles rise to the surface of the lubricant, minimising oxidisation.

Demulsification

Oils can contain additives that enhance the efficiency of your compressor’s water separation capabilities, protecting your system from water and oil emulsions.

Viscosity Under Cold Temperatures

Some oils are less effective in cold temperatures, but specialised air compressor oil maintains a stable viscosity even when temperatures drop.

Different Types of Compressor Oils

Choosing the right oil is essential for your compressor’s performance and longevity. The two main compressor oil types are synthetic and mineral (known as ‘natural’ or ‘standard’). Each has distinct benefits.

Synthetic Oils

Synthetic oil is the most suitable type for high-performance compressors in heavy industries. It can withstand very high temperatures in compressors that operate continuously. Unlike mineral oils, synthetic alternatives require less frequent oil changes, minimising maintenance costs and downtime.

Mineral Oils

Mineral compressor oil, refined from crude petroleum, is a high-value choice for compressors operating in moderate conditions, such as workshops and garages. While it is widely available and easy on the wallet, it requires more frequent oil changes than synthetic alternatives and is less effective in high-pressure environments.

Other Compressor Oils

In addition to standard mineral and synthetic oils, there are options such as biodegradable oils for those who need to minimise their carbon footprint in eco-sensitive environments. Food-grade oils are ideal in industries that need non-toxic lubricants. You might want to search for an oil that complies with NSF H1 standards.

How to Choose the Right Oil for Your Compressor

Factors to Consider When Choosing Oil

The easiest way to determine which oil your compressor needs is to refer to your original equipment manufacturer’s (OEM) user manual. Your manufacturer guidelines may specify which oils are compatible to keep your warranty intact. If you have a bespoke system or need further guidance, keep these factors in mind when choosing compressor oil:

Compressor Type

Different compressor types are compatible with different oils, and some systems work more efficiently with certain types. For example, you may need a low-viscosity oil for reciprocating compressors and synthetic oils for rotary screw compressors that operate continuously.

Operating Environment

If you work with high temperatures, look for synthetic oils with good thermal stability. Dusty or humid environments demand oils with robust anti-oxidation properties.

Viscosity Ratings

It is essential to choose an oil with the correct viscosity rating for your system (you should be able to find these details in your user manual but call us if you need assistance). To determine its thickness, you can look for an oil’s SAE and ISO grades.

Maintenance Intervals

It is worth noting that while long-life oil can be more expensive than standard oil to purchase, it often lasts much longer and can reduce operating costs in the long run.

Common Mistakes to Avoid

Do not attempt to save money by choosing an alternative type of oil. Automotive oils, for example, do not possess the right properties required by an air compressor. Using the wrong type of oil can seriously damage your system.

Also, remember to check your OEM guidelines whenever possible. Using the wrong oil could void your warranty, and deviating from the recommended specifications can result in inefficiencies.

Last but certainly not least, do not overlook your routine maintenance check. Regularly checking the levels and quality of your oil can reduce the risk of system damage and keep your compressor running efficiently.

Benefits of Using the Right Oil

Just some of the key advantages of using the most suitable oil for your compressor include:

• Enhanced compressor performance: using the correct oil minimises friction and heat buildup, ensuring a smooth operation while reducing energy inefficiencies.
• Extended lifespan: oil properly lubricates your system’s components, reducing the impacts of corrosion, deposits, and wear and tear.
• Minimised downtime and repair costs: high-quality oil reduces the risk of breakdowns by protecting parts under demanding conditions.
• Maintain compliance: using oils specified by the compressor’s OEM helps ensure your warranty remains intact and your system complies with industry standards.

Supplying Compressor Oils in Chesterfield, Doncaster, Leeds & Sheffield

If you’re based in Chesterfield, Doncaster, Leeds, or Sheffield, Search Air is your trusted partner for high-performance compressor oils and expert guidance. We supply and support a full range of oils for rotary screw, piston, and bespoke systems across Yorkshire and the Midlands. Whether you need synthetic, mineral, food-grade or biodegradable oil, our team can help you choose the right solution for your specific setup and operating environment. Get in touch today for fast, local support.

Order High-Quality Compressor Oils Today

We have got you covered no matter which type of oil you need to get the most out of your compressor. We have over 78 years of experience at Search Air and are recognised as leaders in our field. For example, we were named Atlas Copco’s Compressor Distributor of the Year in 2022. So, if you need reliable advice and quality products from a team of seasoned experts, you have come to the right place. Call us for more product information and recommendations.

Air compressors are vital to the day-to-day running of businesses in countless industries. Unfortunately, like any other crucial industrial equipment, compressed air systems are prone to problems and breakdowns over time and through general wear and tear. Any downtime can seriously harm your business due to how essential your compressor is to your operation.

A faulty or problematic compressor does not just risk business downtime – it can also lead to unnecessarily high energy bills and greenhouse emissions. Moreover, the repairs can sometimes cost an arm and a leg.

Fortunately, by investing in compressor connectivity solutions, you can minimise the risk of compressor issues resulting in downtime and adversely impacting your bottom line. Essentially, compressor connectivity refers to connecting your compressor to a central hub via technologies such as the Internet of Things (IoT). This allows you to access real-time data on your system’s performance remotely and catch small issues before they spiral out of control.

At Search Air, we are committed to remaining at the cutting edge of industrial compressor technology. That is why we proudly offer connectivity services to bring your operations into the 21st century. Many Atlas Copco compressors can be retrofitted with connectivity solutions, allowing you to use the latest smart tech without investing in a new compressor system.

Naturally, upgrading your compressor can bring a plethora of benefits. In this guide, you will learn about compressor connectivity and the features the latest compressors have. That way, you can decide whether investing in a new system or simply retrofitting your existing system is the wisest investment for you.

Evolution of Compressor Systems

In the not-so-distant past, the only way to monitor the performance of your compressor was manually. Often, this meant that issues could only be identified during scheduled maintenance visits, which means seemingly minor problems such as too much vibration and fluctuating pressures could go unnoticed until they become costly to repair.

Now, thanks to remote monitoring systems, you can track various aspects of your compressor’s performance remotely and in real time—helping you catch inefficiencies before they become costly problems.

To implement compressor connectivity on an existing system, our professionals attach sensors to various elements of your compressor to collect data on parameters such as temperature, pressure, energy consumption, and vibration levels. These sensors access your cellular or Wi-Fi network and transmit the data to a central hub. You can then access this data using an intuitive smartphone app, which makes small issues much faster to detect.

You do not need to rely on data analysis to remain informed. Our connectivity solutions are configured to send you automatic alerts and notifications when something requires your attention.

While existing Atlas Copco compressors can be retrofitted with sensors, there are many advantages to investing in a more modern system. In addition to collecting air pressure and temperature data, modern systems have various sensors that detect operating errors, faulty parts, and unexpected deviations from standard operation. They can even automatically optimise your system to run continuously at maximum efficiency, requiring barely any intervention from you in the meantime.

What Is Compressor Connectivity?

Benefits of Implementing Compressor Connectivity

Whether your workplace relies on a single compressor or multiple units working together, implementing connectivity solutions brings tangible benefits. Being able to see how your system is functioning without manual intervention offers advantages that include:

Automated Notifications for Critical Issues

Connected compressors monitor their performance and health continuously. If a critical issue arises, such as a pressure drop, abnormal temperature fluctuation, or excessive vibration, you will receive a mobile alert automatically and near-instantly, regardless of your location. These notifications enable you to act swiftly when problems arise and can prevent production stoppages and costly breakdowns.

Minimised Equipment Downtime

Thanks to the reliable and timely alerts of connected compressors, you can continuously optimise your system. You will be notified of issues that are not pressing but could benefit from being addressed, such as overheating due to poor ventilation. With fewer breakdowns between scheduled maintenance sessions, you can make preventative maintenance more consistent.

Remote Optimisations and Setups

Thanks to compressor connectivity, you are no longer required to manually configure your system every time changes are made. Instead, you can remotely optimise settings such as flow rates and pressure levels using a simple web or mobile app. This allows you to finetune your system much more easily. Just think of how many working hours you could save with this ability. Plus, remotely adjusting your system makes your workplace more efficient, productive and safe.

Improved Energy Efficiency

The most expensive aspect of running a compressor concerns energy usage. In some industrial settings, compressed air systems can account for up to 40% of the facility’s overall energy consumption. By catching small problems early and optimising pressure levels, you can ensure that your system continuously runs at maximum efficiency, which could shave a significant sum off your annual energy bills. It can also help you comply with ever-changing regulations and minimise your carbon footprint.

Implementing Compressor Connectivity in Existing Systems

Upgrading to a modern and technologically advanced compressor system has many advantages (see above). However, you can still use beneficial connectivity solutions with your existing system. Our experts can carry out a thorough assessment of your current infrastructure to identify gaps in sensor integration. We can then retrofit your model with connectivity tools and modern sensors, often using affordable plug-and-play solutions. On top of bringing your system into the 21st century, we will bring you and your maintenance team up to speed through comprehensive training.

Compressor Connectivity in Rotherham, Nottingham & Manchester

If you’re based in Rotherham, Nottingham, or Manchester, Search Air can help you modernise your compressed air setup with the latest compressor connectivity solutions. Whether you’re looking to retrofit your current system or explore the benefits of Atlas Copco’s smart compressors, our team offers expert support and installation. Gain real-time insights, reduce downtime, and improve energy efficiency—wherever you are. Speak to us today about bringing your system fully online.

Learn More about Compressor Connectivity

If you want to minimise your energy usage, maximise the lifespan of your equipment, and future-proof your business, now is the time to invest in compressor connectivity. Atlas Copco’s latest solutions can result in significant cost savings, ensuring a quick return on investment. Plus, by partnering with us, you can feel confident that you will be kept up to date with the most advanced solutions and upgrades available.

At Search Air, we have been a leading supplier and installer of compressed air systems for over 78 years. We have also been a premier distributor for Atlas Copco since 2001, and we were named their compressor distributor of the year in 2022. If you need a team you can trust, you can count on us. So, give us a call today to discuss the possibilities.

Compressed air systems are crucial to a broad range of industries, from automotive to aerospace. As your system compresses the air, its water vapour can turn into condensation. If too much of this condensation makes its way through your system, it causes wear and tear to your equipment connected to it. You also risk reducing the quality of your end products or services.

In oil-injected compressors, the condensate can also contain minuscule oil droplets. These contaminants may be invisible to the naked eye, but they can wreak havoc on your equipment and the environment if handled or disposed of incorrectly.

Whether you use an oil-injected or oil-free air compressor, high moisture levels can and will degrade your equipment and potentially even put you at risk of breaking the law. This guide will tell you exactly what condensate is, how it forms, the risks of neglecting it, and what you can do about it. We will also discuss the many benefits of properly dealing with compressed air condensate.

At Search Air, we have been an industry-leading supplier and installer of compressed air systems for over 75 years. If you need a compressed air audit, we are only a phone call away – condensate and contamination are just some of the costly and dangerous issues we can identify. Alternatively, we also supply a range of the most advanced Atlas Copco solutions available, equipped with sophisticated water and oil separators that can minimise the risks associated with condensate while improving efficiency and productivity in your workplace.

Call us today to learn more about our energy-saving solutions. Keep reading to learn everything you need to know about compressed air condensate.

Understanding Compressed Air Condensate

Oil-injected compressors release condensate that mostly contains water but can also contain microscopic contaminants and oil particles. So, where does this water come from?

Ambient air in the atmosphere contains a certain amount of moisture, which makes its way into your compressor as the air is pulled into the system through the inlet valve. Moisture in air turns into condensate when it reaches a certain temperature, known as the pressure dew point (PDP). When air reaches the PDP, it can no longer hold water vapour and turns into a liquid state called condensation.

In air compressors, the compression process also causes the air to release condensate in addition to the heating process. For example, if your system works at a pressure of 7 bar(e), it reduces the incoming air to seven-eighths of its original volume, reducing the air’s ability to hold moisture by seven-eighths. Your compressor is fitted with equipment to release this moisture but can rarely eliminate 100% of it.

The amount of condensate released by a compressor is surprisingly high. A 100 kW system operating at 20 degrees Celsius and 60% humidity can release around 85 litres of water over eight hours. The higher the air temperature, the more condensate is produced. For example, a 55 kW compressor operating at 24 degrees Celsius with 75% humidity can produce up to 280 litres daily.

By law, you are required to remove, manage, and dispose of this condensate responsibly. Fortunately, properly managing condensate is advantageous for more reasons than just compliance.

What Is Compressed Air Condensate?

Why Is Condensate Management Important?

Responsible condensate management is crucial for a host of reasons, namely:

Environmental Impact

Condensate can contain microscopic traces of contaminants such as oil that, while not visible, can damage the environment. If discharged without first being treated, condensate from compressors can reduce soil quality, contaminate water supplies, and even harm local habitats.

Equipment Longevity

Poor condensate management can lead to too much moisture working its way through your compressed air system, which can lead to corrosion not only of the system itself but also of all the tools and equipment connected to it.

Energy Efficiency

Mismanaged condensate can reduce the efficiency of your air systems, often causing users to increase pressure levels to achieve their desired result. This not only drives up energy costs but also prevents you from taking advantage of energy recovery opportunities that could significantly reduce waste and boost system performance.

Compliance

Businesses in heavy industries must comply with stringent regulations to protect the environment. Standards such as ISO 8573 set out minimum requirements for air purity, including the safe removal and correct treatment of condensate. Compliance issues can result in fines of tens of thousands of pounds, which could tarnish a company’s reputation and consume a significant chunk of its revenue.

How to Manage Compressed Air Condensate

The best way to find out how to properly manage condensate is to book an air compressor audit with our experts, who can identify inefficiencies and compliance issues before they become costly. Here is what you can do in the meantime:

Inspect Your System

Start by visually inspecting your system as condensate drains to see where it is being directed. Make sure to check all the compressors, dryers, air receivers, and filters. If your condensate is simply being directed to the floor or into simple containers, you will need to treat the water before you can dispose of it to comply with the law.

Install Oil and Water Separators

Ideally, the condensate from your compressed air system should be piped into a water separator (some separators can also effectively separate oil and other contaminants from the water). These separators treat the condensate so that it can be simply drained into the foul water drain (NOT the rainwater or stormwater drains) without harming the environment. Remember that you may need permission from your local water authority before draining your treated condensate.

Learn More about Compressed Air Condensate Management

If you need new oil/water separators to keep your systems in full working condition and your business on the right side of the law, we can help. At Search Air, we have been a leading supplier of advanced compressed air equipment for the better part of eight decades. We were also named the Atlas Copco Distributor of the Year in 2022, so you can trust us for honest advice and recommendations. Call us today to learn more about our effective and efficient separators. Unsure what you need? Book an audit at a time that works with your busy schedule.

Compressed air systems are integral to the day-to-day running of countless businesses in numerous industries. However, like all other industrial equipment, air compressors sustain wear and tear over time, losing efficiency. But it is not just time that can take its toll on your vital tools and equipment.

As businesses grow, their compressed air needs often change. While your system might have been perfectly calibrated until a few years ago, it may no longer be running optimally if your requirements have changed. For example, you might have plugged new tools and equipment into your system without tweaking its settings and calibration for optimum efficiency.

Moreover, tiny inconsistencies in air pressure may now go unnoticed, but the extra electricity required to achieve the air pressure you desire could add up to a small fortune over the space of several months or years.

Fortunately, by hiring our experts for a compressed air audit, you can maximise the lifespan of your equipment while shaving a few zeros off your annual energy bill. You can also do your part to reduce greenhouse gas emissions, remain compliant with ever-changing regulations, improve workplace productivity, and much more. When it comes down to it, a compressed air audit will likely pay for itself in no time.

Below, we discuss the details of compressed air audits, including why you need them, what they involve, their key benefits, and how to prepare for your audit. If you need specific advice, do not hesitate to call us.

Understanding Compressed Air Audits

Compressed air is crucial in various industrial environments, whether packaging food items, powering heavy machinery, processing chemicals, or simply inflating tyres. Even though ambient air is free, producing compressed air can cost an arm and a leg, particularly if your systems are inefficient or faulty.

It is common for air compressors to become wasteful through time or improper usage. Air leaks within the system, infrequent operations, air quality issues, and flow rate inconsistencies can all lead to wasted energy and unnecessarily high running costs. When problems go unnoticed, many people raise the air pressure setting to achieve the required pressure, leading to even more wastage and wear and tear.

A compressed air audit enables you to identify and fix these problems and inconsistencies, which could dramatically reduce your operating costs. In fact, some businesses see up to 50% savings by repairing the issues identified by one of our compressed air audits.

Key Benefits of Conducting a Compressed Air Audit

A compressed air assessment can be a huge benefit to just about any business. Here are just some of the key advantages of a professional audit:

Increased Energy Efficiency

An audit can identify ways to improve the efficiency of your air compressor and find issues that may be causing your system to waste energy.

Reduced Business Downtime

Many workplaces rely on their air compressors for a wide array of daily tasks. If your compressor has an issue, you may not be able to do your job – any amount of downtime can cause serious harm to your business. Call us for an audit, and we will catch small issues before they become costly problems.

Reduced Operating Costs

Increasing your system’s efficiency can translate into significant savings on your operating costs. As mentioned above, some businesses reduce their total energy expenditure by up to 50% following an audit.

Reduced Greenhouse Gas Emissions

Keeping your systems in full working order can significantly reduce your C02 emissions, helping you do your part for the environment.

UK Standards Compliance

Trust us to carry out your audit. You can feel confident that you will always remain compliant with ever-changing quality, safety and efficiency regulations.

Why Do You Need a Compressed Air Audit

Common Issues Identified During Audits

Some of the most common issues found during a compressed air audit include:

Air Leaks

Air leaks in an air compressor can account for up to 50% of the system’s energy loss. They are often caused by poor maintenance, improperly installed connections, and general wear and tear.

Inappropriate Pressure Settings

If your air compressor’s usage has changed, you might no longer have the air pressure settings appropriately optimised, which can lead to premature wear and tear and high energy bills.

Incorrectly Sized Equipment

If you are using dryers, filters, or compressors that are not the correct size for your system’s demand, you may be spending much more than necessary on energy.

Contamination and Moisture Issues

Inadequate drying processes and poor air filtration can lead to contaminants like water, oil, and particles infiltrating the system and damaging your equipment — issues that can be uncovered through professional air quality testing.

The Audit Process – What to Expect

Our experts will thoroughly audit your compressed air systems by first getting to know your workplace’s layout, your equipment’s setup, and your current operational challenges. We will then use sophisticated diagnostics equipment and compressor monitoring systems to track your airflow rates, pressure levels, and energy usage over a set period.

After identifying issues and inefficiencies, we will provide detailed reports with recommended corrective actions and projected savings. The level of audit you require largely depends on the size of your system and needs, but you can rest assured that we will leave no stone unturned.

How to Prepare for a Compressed Air Audit

Depending on your unique situation, we will let you know exactly what we need to perform your audit as efficiently and effectively as possible. However, it will be a great help if you can provide us with documentation such as your system manuals, maintenance logs, and energy usage data. You can also help speed things up by ensuring we can easily access all your equipment, including the piping, end-use points, and compressors.

Book Your Compressed Air Audit Today

At Seach Air, we have been at the forefront of the compressed air industry for over 75 years. We have also been a premier distributor for Atlas Copco since 2001 – and we were named Atlas Copco Compressor’s Distributor of the Year in 2022. If you want a team of highly experienced experts with a proven track record to perform your compressed air audit, you have come to the right place. So, contact us today to book an audit at a time that works with your busy schedule. 

Compressed air systems play a vital role in almost all industries. Businesses often rely on air compressors to power tools, equipment, and machinery in manufacturing and industrial settings. However, compressed air systems are prevalent in many environments, from powering HVAC systems in large commercial buildings to supplying air to medical apparatus in hospitals.

Unfortunately, while compressed air systems bring a host of benefits and practical uses to countless industries, they are energy-intensive. In fact, up to 94% of the electrical energy consumed by an air compressor is converted into heat. Without a heat recovery solution, that energy is simply wasted, which can make your air compressor highly inefficient, costly to use, and damaging to the environment.

Thankfully, heat recovery solutions manufactured by leading brands like Atlas Copco can recover up to 94% of the heat that your compressor would otherwise waste. You can use that recovered energy to heat the interior of your workplace or generate hot water. In some cases, heat recovery can account for up to 70% of a company’s heating requirements, resulting in up to 20% overall energy savings.

At Search Air, we have been a leading supplier and installer of compressed air systems and accessories for over 75 years. We have proudly been a premier distributor for Atlas Copco since 2001 and were named Atlas Copco Compressors Distributor of the Year in 2022. Below, we will explain everything you need to know about heat recovery systems and how they can benefit your business. If you have specific questions about your unique situation, please call us.

Understanding Energy Recovery in Air Compressors

Air compressors are energy-intensive systems, and a significant portion of their energy consumption is converted into heat during the compression process. Without heat recovery systems, this heat is typically lost to the atmosphere, wasting valuable energy. By capturing and repurposing this heat, you can significantly improve energy efficiency while reducing expenses and emissions.

The heat generated by compressors is a natural byproduct of the air compression process and occurs at several points throughout your compressed air system. For example, oil-injected compressors use oil to cool the compression chamber and lubricate the moving parts to prevent wear and tear.

The heat is transferred to the oil, which is then passed through an oil cooler to remove the excess heat. Without a recovery system, this heat is simply wasted but can be captured and reused.

Similarly, aftercoolers can be a major source of heat loss. Once the air in your system is compressed, it is typically too hot to use. An aftercooler releases this hot air, and this heat can be recovered.

As mentioned above, expertly designed and installed Atlas Copco recovery solutions can help you reclaim up to 94% of the heat produced, and this recaptured energy can be utilised in various ways.

Energy Recovery for Air Compressors

Types of Heat Recovery Systems

There are many ways in which recovered heat from an air compressor can be repurposed to prevent unnecessary waste and environmental damage. Hot air utilisation and hot water generation are the two primary types of heat recovery systems in most industrial and commercial settings.

Hot Air Utilisation

In many workplaces, the most cost-effective and straightforward heat recovery system is hot air utilisation, which essentially allows you to redirect the recaptured hot air into areas requiring heating. Instead of allowing your system’s aftercooler to expel the hot air into the atmosphere, we can install ducting systems that channel the hot air to specific areas of your workplace or industrial facility. In some cases, this redirected hot air can account for well over 50% of a business’s overall heating needs.

Hot Water Generation

Hot water generation is a more advanced form of heat recovery. While these solutions can be more expensive to purchase and install than hot air utilisation systems, they are often more versatile and beneficial in the long run in industrial settings. These hot water generation systems work through heat exchangers installed in your compressor’s cooling unit. 

The heat from the oil or cooling water, which has absorbed energy from the compression process, is transferred to clean water via the heat exchanger. Depending on the system design and compressor type, the resulting hot water can reach temperatures up to 90°C.

How water generation systems boast a wide range of commercial and industrial uses, including:

• Cleaning and sanitation
• Process heating
• Central heating
• Boiler feed water
• Industrial washers and equipment

Benefits of Implementing Heat Recovery Systems

Heat recovery systems can bring numerous advantages to your business for your finances, workplace efficiency, and the environment. The key benefits of our advanced Atlas Copco systems include:

Cost Savings

Heat recovery solutions can potentially shave a significant sum off your energy bills. By using the heat generated by your compressor to heat your facility and produce hot water, you can reduce your total energy consumption by up to 15%. Your heat recovery solution will likely pay for itself in no time. This makes them a low-risk, high-reward investment for energy-intensive facilities.

Minimised Environmental Impact

By reusing what would have been wasted heat, you can reduce your reliance on fossil fuels and external energy suppliers with fluctuating prices. Heat recovery systems can also reduce C02 emissions, help you meet your sustainability goals, and remain compliant with ever-changing regulations.

Improved Operational Efficiency

Heat recovery systems manage the heat produced during air compression, effectively removing excess heat from the compressor. This prevents overheating while optimising efficiency. Moreover, compressors that operate at stable temperatures are less prone to wear and tear, which means a heat recovery system can extend the lifespan of your valuable industrial equipment.

Learn More about Heat Recovery Systems for Air Compressors

As you can tell from the above, heat recovery solutions have the potential to bring a range of significant benefits to your business. In fact, our systems contribute much more than just individual business benefits – they could save 1.99% of the total industrial electricity consumption in the UK.

If you want to know exactly how an Atlas Copco system can help your business, do not hesitate to call us. We are an award-winning supplier and installer of advanced solutions with over 75 years of experience. You can feel confident that you are in safe hands when you trust Search Air.

A longstanding family business that rents out plant and machinery to many of the biggest events in the UK, as well as providing industrial air compressor solutions to manufacturers and businesses across the country, is now owned by its employees, after transferring into an Employee Ownership Trust (EOT).

William G Search Limited was established in Leeds in 1946 and employs a team of more than 120 people across offices in Leeds, Liverpool, Manchester, Nottingham and Sheffield. Its clients include compressed air users, the construction industry and many major outdoor events such as Leeds and Reading Festivals and Aintree Racecourse – where it has supplied equipment for the Grand National for almost 50 years. The firm was advised on its EOT by Cathy Cook from Yorkshire based LCF Law.

Richard William Search and his brother, Jamie have owned and run the successful business for the last 35 years. It was originally founded by their grandfather, Bill Search. Richard said: “When it came to succession planning, our children already have successful careers elsewhere, so we were keen to find the right way to secure the future of our firm for the people that matter the most – our team and our clients. We had been approached several times to sell outright to competitors and other big operators in the sector, but we felt this option did not fit with our ethos. We are a family business at heart, and we wanted to do something our grandfather, who established the business 78 years ago would be proud of.”

Richard and Jamie began exploring the EOT option after discussing it with a fellow member of the Business Alliance, which is a local business leaders’ group. They had recently been through the same process. Richard said: “Cathy and the team at LCF Law came highly recommended, so we decided to look into what it involved. The advice we were given was incredibly prudent and we felt it was the perfect solution for us.

“There are lots of benefits to the team, including tax free profit share but most importantly they’re now all stakeholders in the company. By setting up the EOT, our team benefits from the firm’s financial success now and in the future, whilst also leaving a real legacy.

Cathy Cook from LCF Law and Richard Search from William G Search Ltd.

“Crucially, the EOT also safeguards the future of our people and clients for the long term. Our clients can be sure that we remain the safest and most reliable supplier to do business with – we have worked hard to build those relationships, and it was important to us that we retained our approach– so this was a big driver for us. The best people to maintain this culture are the people who have worked with us for years.”

Cathy Cook from LCF Law said: “EOT owned businesses are generally successful in terms of resilience, profitability and staff retention and one of their strengths is that the company can plan for the long term. The Search brothers needed a retirement strategy, but they didn’t want their business to be sold and split up – they didn’t feel at all comfortable with that. They wanted to leave the business in the best possible shape for the future, and as part of that process Richard will be working in the business for at least three more years to manage the transition.”

Richard added: “Of course it’s been an emotional time for us – we wanted to make the right choices and Cathy and her team made it a straightforward process that was delivered on time and within budget. We were delighted that everything went to plan. Our team are now starting to see what being an EOT means, and we are looking forward to a cracking future.”

If your compressed air comes into contact with products or your employees use breathing air sets while at work, you are legally obligated to comply with air quality standards. These standards protect you, your workers, the public, and your bottom line. For a host of reasons, professional compressor air quality testing is essential for more than just abiding by the law.

Compressed air contaminated with oils, dust, and other particles can cause your industrial tools and equipment to degrade prematurely. This can lead to unnecessarily high repair bills in the long run. More importantly, you must keep your air quality optimal to guarantee a flawless finish with your end products.

On top of all that, compressed air quality testing can streamline your overall operations and minimise the risk of business downtime, which can result in a loss of revenue and a tarnished reputation. Fortunately, if you need expert air quality testing from a team of highly qualified technicians, you have come to the right place.

At Search Air, we have been a Premier Distributor for Atlas Copco since 2001, ensuring we only supply and install the highest quality compressed air solutions on the market. Our Atlas Copco-certified engineers use the latest diagnostics equipment to test the quality of your air. Better still, we aim to do it for an unbeatable, high-value price.

Why is Compressed Air Testing Essential?

Here are three key reasons why testing is crucial:

Health and Safety

You might assume that compressed air systems pose little risk to employee health, breathing air testing needs to be carried out every three months. Contaminated compressed air poses a serious risk to your health, even when inhaled in tiny quantities in some cases. Sources of contamination can include onsite industrial or manufacturing processes, vehicle exhaust fumes, filtration issues, and problems with the compressor’s overall performance.

There are many ways in which low-quality compressed air can be hazardous. Low or high levels of gases including oxygen, carbon dioxide, carbon monoxide, and oil particles, can all pose a risk to human health.

Compliance

Low-quality and contaminated compressed air and gases like nitrogen can be harmful, so regulations are in place for safety reasons. You may be obligated by law to undergo periodic air testing in line with industry standards such as the ISO 8753 and the EN12021. 

These standards contain minimum requirements to meet purity classes for your industry.

Fortunately, while compliance seems more like a must than a benefit, it does ensure that your workplace remains operational and safe. It also leads us nicely to the next point.

Equipment and Product Protection

You might think slight alterations in compressed air quality and purity would make little difference to your end products or services. It is easy to see why a petrochemical plant requires a stable level of quality, but the benefits of high-quality air in small workshops may seem less obvious.

However, clean, uncontaminated, high-quality compressed air can extend the lifespan of every piece of equipment that connects to your compressor. You could save a small fortune on repairs in the long run.

Compressor Air Quality Testing

Most Common Types of Contaminants in Compressed Air Systems

Compressed air systems are exposed to various contaminants in all industrial environments, which is why frequent and professional air quality testing is essential. Some of the most common contaminants include:

Particulates

Small amounts of dust, rust, dirt and other particles transported inside your property from outside can all contaminate your compressed air system. These contaminants are abrasive and can cause early wear and tear on any piece of equipment powered by your compressor.

Moisture

Excess moisture and oil contaminants can lead to microbial growth, clogged filters, and equipment corrosion — especially in sensitive applications like food-grade air systems. It can also cause components in pneumatic systems to freeze and rust, especially in colder and humid environments.

Oil Residue

Oil vapours from other compressor components can find their way into your air stream. They can also be present in the air your system initially compresses, even if filters remove most of them. This can lead to clogged filters and expensive mechanical problems without being addressed.

Industry Standards for Compressed Air Quality

Some of the most common industry standards that you may need to comply with include:

ISO 8573-1:2010

This widely accepted standard defines the minimum acceptable levels of particulates, oil vapour, and moisture for compressed air. Classifications range from very pure to general use, depending on your industry and application requirements.

ISO 12500

This standard relates to the performance of your compressed air system’s filters, specifically with regard to oil aerosols, water vapour, and solid particles.

Our Advanced and Certified Testing Methods

We use advanced testing equipment to accurately measure carbon dioxide, oxygen, water, oil, and carbon monoxide levels in your compressed air, compressed air components such as filters, and your breathing air. We are fully qualified to perform these tests in line with UK regulations. We also provide you with a certification of the results so that you know where to make improvements if necessary. With our help, you can stay on the right side of the law while ensuring your workplace remains safe and productive.

Learn More about Compressed Air Quality Testing

Tasks like professional compressed air quality testing in the name of compliance can often seem like a burden – a financial one at that. However, testing is not just about staying on the right side of the law. It is about maintaining workplace safety for your employees, extending the lifespan of your valuable industrial equipment, improving efficiency where possible, and remaining competitive in an increasingly competitive world.

At Search Air, we have been testing compressor/breathing air quality and maintaining compressed air systems for industrial businesses of all sizes for decades. You can feel confident that we will leave no stone unturned when it comes to your safety. We can also highlight ways for you to make improvements that could boost your bottom line. Call us today, and we look forward to providing you with more information.