May 19, 2026
In an air compressor, many high-quality components work together to deliver compressed air or gas efficiently and reliably. However, one component can claim the title of being the most critical of them all, the compressor Air End. This leads us to an important question: what happens if the air end has suffered wear or damage? Can it be replaced, refurbished or repaired?
What is a compressor air end?
A compressor air end or element is the core component of a rotary screw air compressor responsible for compressing air by using intermeshing rotors within a sealed housing. It draws in atmospheric air, compresses it as the rotor space decreases, and delivers high-pressure air for industrial and commercial applications. The air end plays a critical role in compressor efficiency, energy consumption, and overall performance.
Why is the compressor air end even more vital than other components?
Air Ends come in different types, depending on the technology and physical principle. The two main principles of compression are: positive displacement and dynamic compression. Positive displacement refers to compression by reducing the air volume. Technologies that use this principle are pistons, scrolls, and tooth or screw rotors. Dynamic compression uses centrifugal – or turbo – technology to compress air or gas by changing its speed.
Selecting the most suitable compression principle and technology depends on the required amount of air (FAD), pressure (bar) and the air quality needed for your production process. The most widespread industrial compressor type is the rotary screw compressor, either oil-injected or oil-free.
What causes an compressor air end to deteriorate?
All mechanical equipment is subject to wear. Especially in demanding applications or harsh working conditions such as a hot, humid or dusty environment, the performance of the air end may decrease over time.
Increased or uneven tolerances, a damaged coating or a degraded geometry of the screws…
How to recognise deterioration on a compressor air end
- Reduced air pressure or flow output
- Unusual noises (grinding, knocking, whining)
- Higher operating or discharge temperatures
- Increased vibration or imbalance
- Declining air quality (more oil, moisture, or particles)
To avoid excessive energy costs and the increasing likelihood of a breakdown, it is time for action.
What are your options when the air end needs attention?
When a compressor air end shows signs of deterioration, there are three main paths you can take
Repair the compressor element
Restoring the Air End requires specific processes and tools that are only available to the equipment manufacturer. Coating of the rotors is a core technology and when the Teflon coat is worn out, replacing it with a new element is the best way forward.
Opening and reassembling an air end without thorough knowledge will almost certainly result in higher energy consumption, a shortened lifetime and oil contamination of the compressed air.
Replace the air end
All Element types can be replaced. The Atlas Copco Element Xchange program gives you access to the latest Air End technology to restore, and possibly even improve, the original performance of your compressor.
Unlike generically sourced Air Ends, the Xchange program ensures that the new ‘heart’ of your compressor is correctly sized and compatible with the rest of the equipment. In all its details, the new Air End will match the original one.
By avoiding the need to scrap a compressor that is still in good shape, the Xchange program offers you a sustainable solution to keep it in operation.
Refurbishment by Atlas Copco
Refurbishing is offered on all oil-injected rotary screw air ends, at a competitive price with short lead times.
Our dedicated refurbishing centers apply the highest factory standards, with rigorous controls to ensure the reliability and energy efficiency you signed up for when purchasing your compressor.
The refurbishing program gives you the time-saving option to exchange your air end for a refurbished one. While your old element is sent to one of our refurbishing centers, you get a suitable replacement instantly.
What compressor types use an air end?
- Rotary screw air compressors (most common — primary use of an air end)
- Oil-injected screw compressors
- Oil-free screw compressors
- Scroll compressors (use a similar compression element often referred to as an air end)
When are refurbished elements a valid option?
For oil-injected elements only, Atlas Copco offers a high quality refurbishment program. This complies with the same standards all our products live up to, using our factory know-how and Atlas Copco genuine parts.
Why is a genuine oil-free element important for air quality?
The sophisticated technology behind certified Class Zero oil-free air leaves no margin for error. Labyrinth air seals totally separate the oil from the air circuit, and the rotor coating composition and thickness need to be microscopically accurate. If not, even the slightest oil contamination can mean spoilt products and production downtime.
Why not to refurbish oil-free screw compressor elements
Refurbishing or rebearing an oil-free screw compressor element is risky due to its extremely tight tolerances and reliance on precise alignment without lubrication. Improper handling can damage specialized rotor coatings, reduce efficiency, and compromise air quality certification. As a result, non-OEM or poorly executed refurbishment can lead to performance loss, premature failure, and costly downtime.
