Compressor Sizing Guide

Determining the right size of an air compressor involves a few essential steps:

• Identify Your Tools and Their Requirements: Make a list of all tools and equipment that will be using the air compressor. Check each tool's CFM and PSI requirements.
• Consider the Duty Cycle: Assess how often and how long each tool will be used. Continuous operation tools will need a compressor that can handle longer duty cycles.
• Account for Future Expansion: Think about any potential future tools or increased use. It’s wise to choose a compressor that can handle more than your current needs to avoid outgrowing it quickly.

Selecting the appropriate compressor involves considering several criteria:

• Airflow (CFM): Determine how much airflow (cubic feet per minute) is required for your applications. This is a critical factor as it indicates the volume of air the compressor can deliver. Different tools have different air tool CFM requirements, making it essential to understand your specific needs.
• Pressure (PSI): Identify the necessary pressure (pounds per square inch) for your tools and machinery. Various applications will have distinct PSI needs.
• Application: Consider the specific applications and air quality requirements. Take into account any pressure loss due to dryers, filters, or drains. This includes evaluating whether you need a high-pressure compressor or one suited for spray painting or other specific tasks.
• Power (HP/kW): While important, power is not the primary selection criterion. Focus on airflow and pressure first, and then match the compressor’s horsepower (HP) or kilowatts (kW) to your needs.

When sizing an air compressor, it’s essential to understand the difference between capacity and flow rate.

• Air compressor capacity refers to the total volume of air the compressor can hold, typically measured in gallons or liters.
• Air compressor flow rate measures how quickly the compressor can deliver air, usually in CFM.

Both metrics are crucial for ensuring your compressor can handle the demands of your tools and applications.

One method to determine total flow is to consult equipment manufacturers for data sheets. However, the most accurate way is to conduct a “compressed air audit” performed by a compressed air sales professional.

Airflow, also known as free air delivery (FAD), is measured in cubic feet per minute (cfm), liters per second (l/s), or cubic meters per hour (m³/h) depending on your location. Simply put, airflow determines how effectively a compressor can perform a task within an acceptable time frame. The required flow depends on the duration needed to complete a task.

For accurate sizing of your compressor for new or existing applications, always contact a compressed air sales professional for an audit.

Understanding the flow and pressure requirements for your facility is key when choosing an air compressor. Pressure and flow are common terms used when discussing compressed air systems.

Pressure can be measured in pounds per square inch (psi) or bar (metric measure of pressure). Simply put, pressure refers to the amount of force needed to perform a certain amount of work at any given point in time.

The air compressor must provide enough pressure to perform a given task. If 115 psi is required to move the block, anything less will not accomplish the task. It is important to understand the required pressure to size the compressor properly. Otherwise, you may face issues similar to the illustration, where lower pressure fails to move the wooden block or perform the job.

When determining the right compressor, consider both the amount of compressed air flow (cfm) needed and the specific pressure (psi) required for the process. Different tools and applications require specific CFM and PSI levels.

Below is a chart with common tools and their requirements:

• Air Quality: Depending on your application, you might need oil-free or oil-lubricated compressors.
• Energy Efficiency: Consider compressors that have validated energy efficiency ratings to save on operational costs.
• Portability: Determine if you need a stationary or portable compressor based on your workspace and mobility needs.
• Noise Levels: Some compressors operate more quietly than others, which can be essential in noise-sensitive environments.

Find more helpful information in the "Guide to Selecting the Optimal Compressor for Your Needs" ebook or contact us for personalized assistance. Our experts are available to help you determine the best compressor for your operations.

A volume conversion calculator can assist in air compressor sizing calculation accurately. It helps convert different units of measurement to ensure the compressor meets your specific needs. Using this tool can simplify the process of determining the correct size.