Things to consider before you buy a compressor
As mentioned above, energy costs, the initial investment as well as maintenance make up the bulk of the TCO. However, there are also some other factors that are often overlooked.
One of them is the time that you spend choosing the right compressor.
Obviously, this is a major decision, so you don’t want to rush it. On the other hand, you also don’t want to spend more time than you should.
Here is a tip: Atlas Copco offers a wide range of online tools that will help make this decision much easier.
They can tell you which compressor is best for your application and how much money you can save when switching to an energy efficient model.
Atlas Copco experts are also always happy to guide you through the specification process.
Look beyond the compressor
While this may sound counterintuitive (or like the wisdom of a zen master), when choosing your compressor, it is important to look beyond the compressor and its output.
The reason is simple: It would be a mistake to only look at the compressor in isolation, just like it would be a mistake to look at the human heart in isolation instead of as a part of a whole that
includes arteries and organs that have to be supplied with blood.
In countless industrial processes, that lifeblood is compressed air. And, like the human body, a compressed air network only works at its best if all of the different parts work together.
In this case, that means the compressor, the piping, equipment like dryers, aftercoolers, filters, etc., as well as the downstream tools or processes that are powered by the compressed air.
But what does it mean in terms of you designing a better, less expensive system?
Perhaps most importantly, you want to get all of your equipment from a single provider. That eliminates any potential compatibility issues as well as the logistical headaches you face when dealing with various suppliers. In addition, it also reduces your maintenance effort.
Your piping system is another source for potential savings that is frequently overlooked. When designing it, there are various things you should keep in mind.
One of them is to use a loop-type distribution system. That way, the air can flow in any direction and get to the point of use more quickly.
In addition, you should avoid using elbows or tees as much as possible because they cause a pressure drop which you have to compensate by expending more energy.
You should also eliminate quick couplings whenever possible.
Buy today, get ready for tomorrow
If you are reading this eBook, then it is likely that you are thinking about buying a compressor soon. However, you need to keep in mind that the compressor you purchase today will play an important role for your business tomorrow and far beyond.
While compressed air has many benefits, there is also a downside: As noted above, it consumes a lot of energy. That also means the potential for generating a lot of harmful emissions and a large carbon footprint.
That is an issue that has to be addressed – especially at a time when governments are taking steps to meet ambitious climate goals and customers demand greater sustainability.
Therefore, you should keep in mind that the compressor you invest in today has to meet the environmental regulations of the future – and these will likely be much more stringent. In other words, if you are buying a compressor now that barely meets current standards, then you will likely have to purchase another once those standards change.
However, where others see a problem, we see an opportunity. Atlas Copco is leading the way when it comes to designing compressors and associated products that will greatly reduce your carbon footprint.
In terms of efficiency and sustainability, they not only meet the requirements of today’s standards, they often exceed them. And that offers you a real competitive advantage, because you are already prepared now for the tighter environmental regulations of the future.
The most obvious benefit of efficient air compression is the money you save on energy costs. This alonewill often allow you to recoup your investment in a “green” compressor very quickly – especially at a time of high prices and supply uncertainties.
However, there are also several other advantages.
One of them is a reduced carbon footprint. Already important now, this will become crucial in the future. It is clear now that very aggressive action is needed to meet the climate goals world leaders have agreed to.
Since air compression is responsible for 10% of all industrial energy consumption, this is a place where businesses can (and will be mandated to) become more efficient.
And, of course, this also helps you do your part for a healthier planet.
Another benefit of investing in an efficient compressor now is that you can future-proof your operation. This is something you will have to do in the future, so why not get a head start on the competition?
Finally, consumers increasingly want to spend their money on “green” products. An energy-efficient compressor will allow you to show them that you are committed to sustainability and a healthier planet.
Once it comes to selecting the actual compressor, there are various choices that you will have to make. The first one should be what type of technology is best for you.
There are two main types of compressors: piston compressors and screw compressors.
Piston compressors are also known as reciprocating air compressors.
These are simple and robust machines that are usually the least expensive models on the market. They are also easy to maintain and operate.
In addition, piston compressors work well for those on the move. They're small, compact, and adaptable for many environments.
They are also a great starter compressor for those who don’t need all day air flow. That is why you can often find them in workshops, machine shops and small manufacturing facilities.
Rotary screw compressors, on the other hand, are usually the choice when a constant compressed air supply is needed. Because they don’t require cooldown periods, they can deliver air continuously Rotary screw compressors are built for a long lifetime of reliable, energy-efficient operation.
There is great variety in the types and sizes of these compressors, so there is likely a model for any application.
In addition, they can easily be combined with other equipment, such as dryers, to provide you with an entire compressed air system.
While piston and screw compressors are the most common compressor types, there are many more. Check out our Guide to Air Compressors for a more detailed overview.
When it comes to saving money, one of the most important questions you face is whether you want a fixed speed compressor or one with a variable speed drive (VSD).
In most cases, there is an easy answer: Go with the VSD.
The reason is obvious. A fixed speed compressor only has two modes (on and off) and either supplies no air or the maximum amount. However, most applications do not require the compressor’s maximum output at all times.
In fact, in most cases, the demand fluctuates.
That is why Atlas Copco pioneered VSD compressors. Their motor speed adjusts to the respective air demand. This makes them much more efficient. The first VSD models were able to reduce energy consumption by up to 30% compared to fixed speed models.
But Atlas Copco has kept developing this technology and now offers a third generation of VSD compressors – the VSDS series – that can slash your energy consumption by 60% compared to fixed speed models.
Keeping in mind how big of a role energy expenses play in the total cost of ownership of compressors, this can make an enormous difference.
And, of course, a VSD compressor offers all of the previously mentioned benefits of an efficient compressor, such as a much smaller environmental footprint.
Once you have settled on a technology that offers the greatest benefit to your operation, you have to size your compressor.
A model that is too large will result in unnecessary investment and energy costs. A compressor that is too small may be unable to keep up with your demand.
Depending on your application, you will also require additional equipment.
For example, if your air has to be free from any contaminants (moisture, oil and particles), then you have to treat it with dryers, filters, etc.
But there are also other technologies that can help you reduce costs.
One of the ones that can really keep costs down is an energy recovery system. Compressing air not only consumes a lot of energy, it also produces a lot of waste heat. Instead of allowing this hot air to disappear, you can capture and reuse it, for example to heat your facilities.
There are machines for which the controller is not overly important, like your TV, for example, or a garage opener.
That’s not the case for compressors. Here, a controller can greatly improve the efficiency and reliability of a compressor – and save you a lot of money in the process.
Obviously, there are some smaller compressors that have an on/switch instead of a controller. Others have controllers at the unit itself.
More advanced compressors, however, now come with connected controllers that are true marvels of technology.
They allow the compressor to be monitored and controlled remotely, alert their users of potential problems, help detect costly leaks, offer energy optimization suggestions and place an entire library of documents at the fingertips of the operator.
But that’s not all. Atlas Copco has developed the world’s first controller that receives over-the-air updates. That means that the compressor gets better over time as it receives updates and new efficiency-increasing algorithms.
For a multi-unit set-up, a central controller can make a real difference in terms of ensuring maximum operational savings.
Prior to purchasing your compressor, there is one more thing you should do: Think about where to set it up.
This is another decision that deserves careful consideration… and possibly assistance from the experts at Atlas Copco.
First of all, there are some regulatory constraints.
For example, noise protection standards prevent you from setting up a loud compressor too close to where people work.
However, the location of your compressor can also result in significant savings, and this is an area that is often overlooked. A point-of-use compressor can save you a bundle in piping and energy costs.
In addition, you want to set up your compressor in an area where the intake air is especially clean (i.e., where it contains minimal dust, moisture or other contaminants).
That not only increases the reliability of the unit but can also greatly reduce your air treatment costs because you will need less filtration, a less energy-consuming dryer, etc.
The ambient temperature also plays a large role in keeping costs down. For every reduction of 5°C, you can achieve energy savings of 1.5%. And that quickly adds up.
