When to replace your air compressor?

Compressed air is an essential component in any modern manufacturing facility, and it is often referred to as the 4th utility. 

Having a reliable source of compressed air is critical. As plant efficiency and profitability take centre stage many facilities have just enough compressors to meet the plant demand. Like any other plant utility, a good maintenance regime needs to be followed to maximize availability. But as the compressor units start ageing it’s important to plan for a timely replacement. Otherwise, an unexpected failure could trigger production delays, leading to lost revenue and profit. 

Compressors typically have an average life span of 10-15 years considering the harsh climate conditions that prevail in India. Typically, a user should start thinking of compressor replacement from the 7th year onward depending upon the running hours within each year as the unit approaches the time for an overhaul. Ageing also impacts some of the major compressor components such as the motor, the coolers and the compressor element itself. This has a negative impact on efficiency and increases the risk of sudden failure. 

Are you aware that energy or power contributes up to 80% of the total life cycle cost of an air compressor? 

If the impact of aging-related energy loss is accounted for, coupled with the fact that newer generation compressors are more efficient, it would be worth investigating the option of replacement much sooner. And if the risk of breakdown and the impact of delayed production is factored in it becomes apparent that it is wiser to replace rather than repair.

Compressors, like all other equipment that operate continuously around the clock, have an escalating maintenance cost linked to aging. This escalating maintenance cost is easily saved by investing in a newer compressor. 

In addition to this, an ageing compressor loses efficiency, and this efficiency loss increases as the compressor start reaching its due overhaul. Even after overhaul, the compressor might not reach its peak efficiency like a new unit. 

However, before making your decision it’s best to check the condition of your compressors for energy consumption & operational efficiency.

Atlas Copco iiTrak audit gives an insightful report that provides a good snapshot of the state of your compressed air system. Our specialists will visit your compressor room and utilize data loggers to measure your system and gather the needed information. 

Data loggers will be attached to the air compressor for a minimum of 7-14 days in order to observe and record all trends and demand fluctuation during the weekdays as well as the weekend. 

Results of the audit will provide you with a good understanding of the actual compressed air usage over a period of time. It will allow you to identify air demand peaks and the overall consumption pattern. 

Our air audit will give you a better understanding of your system and its inefficiencies. And all the data and advice you need to make a decision on whether to invest in a new system or continue with the maintenance of the existing system.