ELGi oil-free air compressors provide Class-0 certified oil-free air, that is compliant with ISO 8573-1 standards.
https://www.elgi.com/eu/oil-free-compressors/
2. Introduction
Clean Compressed Air for Sensitive Environments
Understanding Oil-Free Screw Air Compressors
Choosing an Oil-Free Compressor
Advantages of Oil-Free Compressed Air
Industries Benefiting from Oil-Free Screw Air Compressors
What Can Businesses Gain from Oil-Free Air Compressor Maintenance
Is an Oil-Free Screw Air Compressor Right for Your Plant?
Conclusion
TABLE OF CONTENTS
3. In certain industries like pharmaceuticals, food and beverage, and electronics,
clean compressed air isn't a luxury, it's an absolute necessity. Contaminated
compressed air in these sensitive environments can trigger a chain reaction of
problems,fromproductintegrityissuestodamagedequipment,increasedcosts,
and even potential health risks. Furthermore, a damaged reputation could prove
to be the ultimate setback for any company.
Oil-free screw air compressors are designed to eliminate the risk of oil
contamination. These compressors play a vital role in preserving compressed air
quality. In this ebook, we'll explore why clean compressed air is crucial in these
industries and how oil-free screw air compressors emerge as the champions of
compressed air purity.
INTRODUCTION
4. Sensitive environments are the industries where product quality, safety, and
compliance with stringent regulations are of utmost importance. These settings
demand the highest standards of compressed air purity to safeguard both the
products and the individuals involved in these processes.
Sensitive environments include, but are not limited to:
Food and Beverage Industry
Electronics Manufacturing
Pharmaceuticals
Cleanrooms
The presence of contamination in such environments can lead to significant and
widespread repercussions. It can result in diminished product quality, a surge in
product recalls, unwanted downtime, equipment wear and tear, and
non-compliance with stringent regulations.
Dry Particles: These can include pollen and dust. Sources encompass
manufacturing processes, outdoor pollutants, and internal system wear and
tear.
Water and Water Vapour: Compressed air naturally contains moisture, which, if
excessive, can interfere with industrial processes and lead to corrosion in
equipment.
Oil Mists and Vapours: Oil contamination can occur in the form of droplets,
aerosols, or vapours and poses a risk to product quality. Monitoring and control
are vital in industries like pharmaceuticals.
CLEAN COMPRESSED AIR FOR SENSITIVE ENVIRONMENTS
5. UNDERSTANDING OIL-FREE SCREW AIR COMPRESSORS
Why Clean Compressed Air Matters
The repercussions of compressed air contamination in sensitive environments
are profound. Contaminants such as oil, dust, bacteria, liquid water, aerosol, and
dry particulates can lead to:
Lower product quality
Increased product recalls
Unnecessary downtime
Equipment damage
Compliance violations
In sensitive environments, clean compressed air isn't just an advantage; it's a
necessity. This chapter emphasises the importance of clean compressed air and
introduces the critical role that oil-free compressors play in these environments.
Oil-freescrewcompressors,aspecialisedtypeofrotaryscrewcompressors,are
distinguished by their capacity to provide high-quality, oil-free compressed air,
rendering them indispensable in compressed air-purity critical industries.
Designed to mitigate the perils of oil contamination, they strictly adhere to
compressed air quality standards, guaranteeing the production of oil-free,
contaminant-free compressed air.
Oil-free screw air compressors consist of several key components that work
together to efficiently compress air without the use of oil in the compression
chamber. The core structure and principles of operation include:
6. Rotors: At the heart of an oil-free screw compressor are two rotors, often
referred to as helical screws. These rotors are precision-engineered and
designed with a specific helical shape that rotates in opposite directions within a
closed chamber to compress the incoming air.
Air Intake: Ambient air, containing various contaminants and impurities, enters
the compressor through an intake filter. The filter helps remove larger particles
and prevents them from entering the compression chamber.
Compression: As the rotors rotate, they draw in and compress the incoming air.
Thehelicaldesignoftherotorseffectivelytrapsandsqueezestheair,reducingits
volume and increasing its pressure.
Cooling: During compression, the air can become hot. Oil-free screw
compressors typically use air or water cooling systems to maintain the desired
operating temperature and prevent overheating.
Oil-Free Operation: One of the distinguishing features of these compressors is
their oil-free operation. Unlike oil-injected compressors, there is no oil injected
into the compression chamber to seal, cool, or lubricate the rotors. Instead, they
rely on a combination of tight tolerances and advanced materials to operate
without the need for oil or they use water-injection in place of oil-injection.
Discharge: The compressed air at the desired pressure is then discharged and
madeavailableforvariousapplications.Thishigh-quality,oil-freecompressedair
is ideal for use in sensitive environments and industries with stringent
compressed air quality standards.
7. Selecting the right air compressor is a crucial decision for any industry. It's not a
one-size-fits-all choice; your selection should align with your plant's specific
requirements. In sensitive environments, choosing an oil-free screw compressor
is often the wisest decision to ensure clean, contaminant-free compressed air.
Factors you should consider when choosing an oil-free compressor
Compressed Air Quality Standards: Understanding the compressed air
quality standards required for your industry.
Air Demand: Determining your plant's air demand and flow rate.
Environmental Impact: Evaluating the compressor's impact on the
environment.
Maintenance Needs: Assessing the maintenance requirements.
Energy Efficiency: Considering the compressor's energy efficiency.
Right Size: Properly sizing your compressor ensures optimal performance
and cost-effectiveness.
Additional Factors to consider
When choosing an oil-free screw air compressor, several other factors come into
play. These factors are crucial for maximising the benefits of oil-free technology:
Compact Design: The compact design of oil-free air compressors allows for
space-efficient installation. In environments where space is at a premium, these
compressors offer a practical solution, allowing you to maximise your
workspace.
CHOOSING AN OIL-FREE SCREW AIR COMPRESSOR
8. Low Maintenance Costs: Compared to oil-lubricated compressors, oil-free air
compressors typically have lower maintenance costs. This means fewer
expenses on maintenance, repairs, and replacement parts, contributing to
overall cost savings.
Lowest Ownership Cost: While the initial investment in an oil-free air compressor
may be slightly higher, the total ownership cost over the compressor's lifetime is
lower. With energy savings, reduced maintenance costs, and longer-lasting
components, the total cost of ownership is one of the most compelling reasons
to choose oil-free air compressors for your industrial needs.
ELGi AB Series oil-free screw air compressors are specially designed to meet all
these factors that will benefit you and your business to soar.
Oil-free screw air compressors are well-suited for applications that demand the
highest compressed air purity standards and where any level of oil
contamination can have serious consequences. Let us now understand the
advantages of oil-free compressors.
Eliminating the Risk of Contamination: Contamination risks in manufacturing can
lead to lower product quality, increased recalls, and downtime. Oil-free air
compressors prevent oil from entering the compressed air, ensuring peace of
mind for manufacturers, protecting their brand, and reducing maintenance
costs. Oil-lubricated compressors introduce trace amounts of oil, leading to
higher maintenance and replacement expenses. Transitioning to oil-free
compressors minimises these risks and reduces maintenance costs
ADVANTAGES OF OIL-FREE COMPRESSED AIR
9. Reducing Environmental Impact: Oil-flooded compressors need frequent oil
changes, every 6-12 months, leading to significant oil consumption. Disposing of
this oil requires adherence to environmental guidelines. In contrast, oil-free
compressors don't use oil for compression and need oil changes only every 2-3
years, promoting sustainable manufacturing. Oil-free compressors produce
condensate that can be easily discarded or recycled within the plant, reducing
the environmental impact.
Lowering Maintenance Costs: Switching to oil-free screw air compressors
reduces maintenance requirements. Benefits include fewer components to
maintain, longer intervals between oil changes, no need for costly oil filters,
elimination of oily condensate management, longer desiccant life for
downstream air dryers, and reduced labour and outage costs.
Decreasing Energy Costs: Energy costs represent a substantial portion of air
compressor life-cycle expenses, typically 75%(Source: ScienceDirect).
Oil-flooded compressors have multiple oil filters and separators causing
pressure drops, lower air pressure delivery, and increased energy use. Oil-free
compressors operate efficiently, delivering high-pressure compressed air,
resulting in energy savings and significant cost reductions.
10. With multiple utilisation to fulfill the demand for clean compressed air, let us now
explore how oil-free air compressors can benefit different industries.
Pharmaceutical Industry
Inpharmaceuticalapplications,cleanlinessisofutmostimportancetoensurethe
quality and performance of products. Any trace contaminants like oil or moisture
can have serious consequences. Manufacturers must minimise contamination
risks throughout the manufacturing processes, including tablet coating and
product drying, by utilising the highest class of compressed air purity. Oil-free
screw compressors are indispensable in this sector to meet the stringent
compressed air quality requirements.
Food and Beverage Industry
The food and beverage industry faces increasingly strict regulations regarding
product safety and cleanliness. To avoid contamination and product recalls,
manufacturers must use clean compressed air throughout the production
process. While specific regulations may not yet exist, companies must establish
their own risk management programs to determine acceptable levels of
contaminants, including particles, water, and oil. Oil-free screw air compressors
play a critical role in ensuring the integrity of products in this industry.
Electronics Industry
In the electronics industry, maintaining clean and dry compressed air is critical to
minimise trace contaminants in the final products. Oil-free air compressors help
protect sensitive instrumentation and ensure the highest quality of finished
electronic devices. As electronic parts and equipment become smaller and more
intricate, the need for contaminant-free air is even more pronounced.
INDUSTRIES BENEFITING FROM OIL-FREE SCREW AIR COMPRESSORS
11. How can your business benefit from a highly efficient oil-free air compressor?
Numerous industries necessitate a particular focus on maintaining clean
compressed air. If your business falls into this category, discover how you can
benefit from it below.
Environmentally Friendly
Inadequate maintenance causes energy wastes of up to 25% of a compressor's
output and increases the leak rate by 20%. Proper maintenance ensures
efficiency, minimizing the environmental impact.
Zero Downtimes
Downtimes are detrimental, disrupting production schedules and causing client
delays. Oil-free compressors reduce repair frequency. Preventive maintenance
prevents sudden breakdowns and worn-out parts, ensuring smooth operations
and early detection of issues like air leaks.
Cost-Saving
Preventive maintenance saves costs by avoiding sudden breakdowns, worn-out
parts, and inefficiencies. Detecting problems like compressed air leaks in
advance leads to efficient operation and lower energy expenses.
Safety and Compliance
A malfunctioning air compressor poses risks to employees and jeopardises
production standards, potentially hampering your business. Preventive
maintenance safeguards operations, ensuring safety and compliance.
WHAT CAN BUSINESSES GAIN FROM OIL-FREE
AIR COMPRESSOR MAINTENANCE
12. Is an oil-free air compressor the right choice for your plant? By analysing your
energy costs and maintenance spending, you can make an informed decision
about whether oil-free air compressors, like those offered by ELGi, are a good fit
for your plant's needs.
ELGi Application Stories
Whether you're delving into Europe’s pharmaceutical sector, marked by strin-
gent quality standards and the costly consequences of poor-quality products,
or looking at the versatile uses of compressed air in medicine production, these
stories underscore the irreplaceable role of oil-free compressors. In pharmaceu-
tical manufacturing, compressed air plays a vital role in critical processes,
including pill coating, conveying, and jet milling, safeguarding product quality,
and averting contamination risks.
ELGi AB series oil-free screw air compressors eliminate the need for oil and com-
plex filtration systems, making them an optimal choice for industries like phar-
maceuticals.
Explore more application stories to witness the importance of oil-free air com-
pressors.
IS AN OIL-FREE SCREW AIR COMPRESSOR RIGHT FOR YOUR PLANT?
13. In conclusion, oil-free screw compressors offer numerous advantages across
diverse industries. They deliver 100% oil-free compressed air, ensuring contami-
nation-free operations, reduced environmental impact, lower maintenance
expenses, and decreased energy costs. These compressors are indispensable
in critical sectors such as pharmaceuticals, food and beverage, and electronics,
where compressed air purity is non-negotiable. Along with this, choosing the
right oil-free air compressor manufacturers is also crucial.
Investing in oil-free technology today boosts your finances as well as supports
environmental preservation for generations to come. It's a win-win scenario,
promoting operational efficiency, cost savings, and a meaningful stride toward
a cleaner and greener future. ELGi shares the same goals and hence designs
oil-free screw air compressors for sensitive environments. Interested in ELGi’s
services and parts? Get in Touch.
CONCLUSION
