Services
Air Compressors for Aerospace
In the aerospace industry, compressed air isn’t a simple utility; it’s a mission-critical asset integral to quality, safety, and operational performance. With bases in Leeds, Sheffield, and Nottingham, Search Air designs and maintains these mission-critical compressed air systems for aerospace manufacturers and MRO facilities across the Midlands and North.
The industry’s intolerance for faults means that the quality, pressure, and dew point of the compressed air supply all affect the integrity of high-value components. An unreliable system that fails to meet these exacting requirements can lead to costly product rejections, production downtime, and unacceptable safety hazards.
We cover the technical specifications required for aerospace compressed air systems, from requirements for Class 0 oil-free air to delivering regulatory compliance and maximising energy efficiency.
Why Aerospace Demands More Than Standard Industrial Air
While compressed air drives industrial processes across various sectors, its role in aerospace manufacturing and MRO is on a different level. One errant droplet of oil or excess moisture will quickly find and ruin a component. Contaminants in compressed air can break the structural integrity of a composite part, ruin a multi-layer paint finish, or lead to the failure of sensitive avionics.
Compressed air systems also represent a big slice of an operation’s running costs. The British Compressed Air Society (BCAS) estimates that in the UK, compressed air can account for as much as 10% of all industrial electricity consumption. Optimising that system, then, is a direct route to cutting costs and meeting energy management targets.
Air quality is non-negotiable in these processes:
- Precision Manufacturing: CNC machines, composite lay-ups, autoclaves, or other processes that rely on clean, dry air as a stable, contamination-free source of power.
- Surface Finishing and Paint: ISO-classified clean, dry air can be used to atomise coatings in surface finishing, avoiding expensive coating failure such as blistering, fisheyes, or pinholes.
- Instrumentation and Labs (CDA): Supplying air with a very low-pressure dew point (PDP) for stable measurements and component conditioning.
- MRO & Component Testing: Driving pneumatic tools, cleaning critical components, and performing leak and pressure tests on hydraulic and fuel lines.
- Ground Support Equipment (GSE): Powering equipment from maintenance tools to Air Start Units (ASUs) for engine ignition.
The Purity Mandate: Understanding ISO 8573-1:2010 Class 0
The global benchmark for air purity is the ISO 8573-1:2010 air quality standards, which classifies compressed air based on the maximum allowable concentration of particles, water, and oil. For critical aerospace processes, the distinction between oil purity classes is fundamental.
| Oil Purity Class | Max Oil Content | How Achieved | Risk Level |
|---|---|---|---|
| Class 1 | ≤ 0.01 mg/m³ | Oil-injected + filters | High (filter failure = contamination) |
| Class 0 | None introduced | Oil-free by design | Minimal |
Applications that have direct contact with the part, such as paint, composites, or avionics, are best suited for a Class 0 system, which can only be provided by true oil-free air compressors to eliminate the risk of oil contamination.
Specifying the Right Equipment for Aerospace Applications
A truly aerospace-grade compressed air system for plant air is a combination of the compressor, air treatment, and distribution network. Typical aerospace plant air pressure is usually 6–10 bar(g). Systems need to be set up to meet this demand reliably. As an Atlas Copco Premier Distributor, Search Air only specifies equipment that has been designed to meet the industry’s requirements.
Class 0 Oil-Free Compressors
For process-critical applications, an oil-free compressor is essential. The primary choices are:
- ZR/ZT Oil-Free Rotary Screw: These are the workhorses for aerospace facilities, delivering certified Class 0 air with options for water cooling (ZR) or air cooling (ZT). Models with Variable Speed Drive (VSD) offer significant energy savings.
- ZH Oil-Free Centrifugal: For large OEM plants with very high, continuous air demand, ZH series centrifugal compressors provide exceptional efficiency and reliability at scale.
Utility Air Systems
For non-critical applications, such as powering tools in a workshop physically segregated from clean manufacturing areas, an oil-injected compressor may be suitable:
- GA VSD+ Oil-Injected Rotary Screw: These highly efficient units are ideal for general tool air. They should never be used to supply air for paint, composites, or other sensitive processes. Options with integrated dryers are available for compact tool air systems.
Essential Air Treatment
Pure air isn’t enough. You also need to remove moisture and particles concentrated during compression.
- Air Dryers: To prevent corrosion and moisture contamination, aerospace systems often require a pressure dew point of -40°C or lower. This is achieved using heatless or blower-purge desiccant dryers. For applications requiring maximum energy efficiency, heat-of-compression (MD/ND) dryers utilise the compressor’s own heat to regenerate desiccant, resulting in minimal energy costs.
- Piping and Filtration: A complete filtration train removes solid particles to the required ISO class. The distribution network should consist of materials like AIRnet aluminium piping, which prevents corrosion, ensures low pressure drop, and features leak-free fittings.
System Control and Monitoring
Modern systems benefit from advanced remote monitoring and automation. Atlas Copco’s SMARTLINK system provides real-time data on system health, enabling predictive maintenance to prevent downtime. For sites with multiple machines, an ES central controller optimises the entire compressor room to operate at the lowest possible energy cost.
Optimising for Energy Efficiency and Cost Control
A well-designed system not only guarantees air quality but also delivers significant operational savings.
Energy-Efficient VSD Technology
A Variable Speed Drive compressor automatically adjusts its motor speed to match air production with real-time demand, cutting energy use by up to 50% in facilities with fluctuating loads.
Heat Recovery
Up to 90% of the electrical energy used by a compressor is converted to heat. Heat recovery units capture this thermal energy to produce hot water for space heating or process use, reducing boiler load and cutting site-wide energy bills.
Leak Management
According to BCAS, leaks can waste up to £1,200 per year per 3 mm hole at 7 bar. A programme of regular compressed air leak detection using ultrasonic equipment offers a rapid return on investment.
Energy Audits
Professional compressed air audits provide the data needed to make informed optimisation decisions and give the auditable data required for compliance with ESOS, SECR, and ISO 50001.
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Energy-Efficient VSD Technology
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Heat Recovery
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Leak Management
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Energy Audits
Looking to upgrade your system or reduce compressed air energy costs? Ask our team for a no-obligation site assessment and energy audit.
UK Compliance and Lifecycle Support from Search Air
Operating a compressed air system in the UK requires adherence to strict health and safety regulations. All equipment and testing protocols we provide align with ISO 8573-1:2010, ISO 12500 (filters), and ISO 7183 (dryers). As an engineering partner, Search Air ensures your system is fully compliant. We provide expert support for:
- PSSR 2000 (Pressure Systems Safety Regulations): Including the provision of a Written Scheme of Examination (WSE) and competent person inspections.
- PUWER, F-Gas, and ATEX/DSEAR requirements.
Based in depots across Leeds, Sheffield, and Nottingham, Search Air is the trusted partner for air compressors for aerospace applications. We actively support aerospace facilities across Derby, Sheffield, and Nottingham with Class 0-compliant systems. We are an employee-owned company, which means our team is invested in our customer success. All engineers are qualified PSSR, F-Gas, and Confined-space working, supported by full Health & Safety accreditations, including CHAS, SafeContractor, ISO 9001, ISO 14001, and ISO 45001.
Available services include tailor-made air compressor installations, fully bespoke preventative maintenance plans, and 24/7 emergency call-out support to ensure maximum uptime.
Frequently Asked Questions
What does ‘Class 0’ oil-free really mean?
It means the compressor introduces no oil at all into the air stream, by design, not by filtration. It’s the only way to guarantee contamination-free air in critical aerospace processes.
What’s the return on investment for upgrading to VSD or heat recovery?
Most aerospace facilities see ROI within 6–12 months due to energy savings and reduced downtime. For systems with leaks or inefficiencies, payback can be even faster.
Do I need to shut down my system to inspect it?
No. Our team utilises ultrasonic and thermal inspection methods, enabling comprehensive diagnostics during live operation.
Your Partner for Mission-Critical Air
A compressed air system is a complex, engineered asset for the aerospace industry. Specialist design, installation, and lifecycle support are required to ensure the purity, reliability, and efficiency your operation needs. Partner with a trusted provider to power your business with a secure, compliant, and performance-optimised solution. system
Book a free on-site audit or ask for a custom system proposal to meet Class 0 purity and PSSR compliance requirements for your aerospace operation.
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