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Did you buy the wrong type of compressed air dryer?

Do you have a desiccant compressed air dryer in your plant?
Yes?
Do you know the annual running cost of that dryer?
It's plugged into a power socked, so it probably uses a bit of electricity… and you need to replace the desiccant every so many years. Right?
True!
But for many types of desiccant air dryers, there's a hidden cost… and it is substantial!
In fact, the yearly cost will probably SHOCK you!
The culprit?
Purge air!
Purge air is air that is used to regenerate the desiccant. (the desiccant needs to be regenerated every few hours, to remove the water that it previously absorbed).
There are 2 main types of desiccant dryers:
Heated blower regenerated
This type uses an external blower and heater to regenerate the desiccant.

It requires only electricity (around 1 kW for every m3/min of compressed air).
Purge regenerated
This type doesn't use electricity to regenerate the desiccant...
Great, right! 
No! 
It uses precious compressed air!!!
This compressed air flow is between 10 and 20% of na…
Recent posts
4 Ways to Extend Your Air Compressor’s Life
Intelligent management of maintenance and operations of the plant’s compressed air system helps increase plant uptime, reduce unplanned shutdowns and help keep the plant profits and employee morale at peak levels. Service Agreement for Out-Sourced Compressor Maintenance With a full range of coverage options available, service provider inspects your air compressor for wear, damage and potential failure. Below are three different types of Air Compressor Service Agreements and their key benefits: OEM Service Schedules – Offer compressed air maintenance according to scheduled service intervals. Includes 46-point compressor inspection, filters and fluid.Annual Maintenance Agreement— Sakoon offers annual service agreements to relive plant managers from hassles of air compressor maintenance so that they may focus on production.Trouble Shoot Plan— System Failure – Call the Professionals! Should your system ever fail, customers can contact Sakoon spec…
Decoding the Duty Cycle Rating of Piston Compressors

Selecting the correct air compressor for your application can be a complicated process. Before making a purchase, operators need to specify the quality and amount of air their application requires. Each compressor technology (rotary, piston, centrifugal, etc.) has an optimal flow output, so users should choose compressor technology based on the compressed airflow requirement of their application. Some compressors, like rotary screw and centrifugal, are designed to run continuously at full speed while maintaining peak airflow (defined in cubic feet per minute, or CFM). The motors and cooling systems of these compressors are engineered to run 100 percent of the time without overheating. However, this isn’t true for all compressors. Piston compressors do not have the cooling capabilities to run continuously for extended periods of time. Therefore, each piston compressor must have a specified flow output and pressure, as well as the perc…
Splash and Pressure Lubrication in Piston Compressors
Piston compressors have been around for centuries. They can be either oil-injected or oil-free, depending on the application and end use. In oil-injected models, the oil typically serves three crucial purposes: cooling, sealing and lubricating. But not all oil-injected piston compressors lubricate components the same way. There are two common methods of lubricating the pump in piston compressors: splash and pressure lubrication.

Splash lubrication In splash lubrication, oil is applied to the cylinders and pistons by rotating dippers on the connecting-rod bearing caps. Each time they rotate, the dippers pass through an oil-filled trough. After running through the oil trough, the dippers splash oil onto the cylinders and pistons to lubricate them. While splash lubrication is effective for smaller engines and pumps, it’s not a precise process. Parts of the pump may be insufficiently oiled or oiled too much. The amount of oil in the trou…

Using Compressed Air? Think again!

Using Compressed Air? Think again!
We know this might sound strange from a guy who's all about compressed air... ... but did you ever wonder WHY and IF you really need to use compressed air? It might have been a very bad decision to make use of compressed air for your tools, machines, actuators, etc. Sure, some applications DEMAND compressed air. It's simply the only real option for it. And we know, compressed air and has many upsides: compressed air tools are very powerfulthey are safe to usecan operate in very dirty environmentsare cheaper compared to their electrical counterpartscan last a lifetime. I love all the benefits that using compressed air for your application brings.. but there is one very big downside..
Compressed air is EXPENSIVE.Very expensive.In fact, it's 7x - 8x more expensive compared to electricity. We talked about the cost of compressed air. And here's an example that shows exactly how and why using compressed air is 7x more expensive than electric…

A VSD Compressor Doesn’t Save You Money

VSD (Variable Speed / Frequency Drive) Compressors

The energy savings were huge… of course. The pay-back time would be a few months, or days, or less.. for sure!

Stop here!

Yes, a VSD compressor can save huge amounts of energy (and thus money), but only if a propoer homework is one, make some calculations and use your common sense.

[For those in the dark: a VSD or variable-speed compressor uses a frequency drive to match the compressor speed (and thus capacity) to the amount of compressed air needed. This as opposed to 'load-unload' machines that runs at a fixed speed but 'loads' and 'unloads' between a minimum and maximum pressure).

And IF a VSD compressor is a good idea in your situation, buy the right size of VSD compressor.

Here's when a VSD compressor will save you money: when it runs at less than 80% speed for most of the time and when it runs continuously (daily).

In these cases, the cost-savings can be huge. Tens of thousands of dollars per year in energy …

3 Ways to Save Money On Compressed Air

3 Ways to Save Money On Compressed Air


What if you knew that your compressed air system was completely optimized… running happily day after day.
No more waste of money and electricity…

Because let's face it: wasting thousands of dollars per year on electricity, without you knowing it, sucks.
Want to optimize your compressed air system?

It's impossible to share the complete step-by-step system in an email, but I can get you started on the right path.

Compressed air optimization #1: Air leaks As discusses in our previous blog: fix those leaks!

Compressed air leaks are the number one energy wasters!

The biggest, most rewarding, leaks will be easy to find. For the smaller leaks, you might have to do some extra work, but it will pay off!

But more importantly, once you fixed most of the leaks, put a system in place to continually check for and repair new compressed air leaks.

You can also use some stealth tactics like dividing your compressed air network in zones and shutting of those zones t…