How to choose the right compressor – 7 key factors

Compressors are used in various industries, and there are many types, sizes, and brands available on the market, making it challenging to select the right one. When evaluating our clients' air compression needs, Ivys’s compressed air specialties consider the following seven key factors.

1. Compressor Capacity and Size

Picking the best air compressor for your facility is essential to keep production running smoothly and save energy costs.

What will your compressor be used for, how many tools will be needed, and what flow will be required? Evaluate the PSI requirements of the tools and processes for your application and facility.

Air audits are an excellent way of determining a plant's compressed air utilization. A wealth of data is available to calculate your capacity requirements, and our compressor solutions experts can help you evaluate your needs.

2. Duty cycle & utilization        

The duty cycle refers to the amount of time a compressor is expected to run at total capacity each hour. Will your compressor need to run all day or occasionally?

When choosing a compressor with the best life cycle cost, consider the following guidelines.

• If usage is less than 4 hours/day, choose a reciprocating compressor.
• For usage between 4 and 8 hours/day, a belt-driven screw compressor is recommended.
• If usage exceeds 8 hours/day, a direct-driven screw compressor is the most suitable option.

3. Quality of Air 

Industrial compressors use oil to cool, lubricate, and seal moving parts, exposing compressed air to the oil.

The selection of the air compressor will vary depending on your specific application requirements.

In specific applications, compressed air comes into direct contact with products such as food and pharmaceuticals, making oil-free air the preferred choice.

For critical and sensitive applications, choose a compressor with class zero air, free from oil residue all the time.

How much maintenance will be required will depend on your application and choice of compressor.

4. Maintenance requirements

How often consumables need to be replaced will determine how much time must be dedicated to their replacement.

Is the compressor designed for easy access to components to minimize service time?

When comparing compressors, there are several elements that can reduce maintenance time.

Two-stage filtration will increase the life of the consumables when compared with single-stage filtration, increasing uptime between scheduled maintenance and, in turn, increasing productivity.

Other features also reduce maintenance. For example, a non-touchless rotor will perform consistently throughout the compressor's life.

Factors like open or closed loop water circuits for cooling are also important for maintenance considerations. Closed loop systems eliminate the need for a water purifier on the inlet, making it one less filter to change. Auto-water replenishment systems, such as the Elgi AB series, reuse the condensate water to auto-replenish the tanks with fresh, clean water.

5. Energy Efficiency

Energy costs comprise over 76% of a compressor's total life cycle cost (LCC). Therefore, your compressor's energy efficiency can significantly reduce operating costs by cutting utility expenses.

Overall life cycle cost of compressors

Increased energy efficiency also reduces greenhouse gas emissions which can support a facility's environmental, social, and governmental (ESG) goals by improving energy efficiency.

Rotors play a critical role in compressor functioning, and their design significantly impacts energy efficiency. If the rotors do not run optimally, this can lead to pressure losses, reduced operating speeds, increased consumption, and maintenance needs.

6. Health and Safety

Health and Safety compliance is not optional, so understanding your facility's requirements and selecting a compressor that meets or exceeds these is paramount. Depending on your application, various standards apply to regulating valves, relief valves, controls, water quality, air quality, and electricals. Our air compression experts have been supporting clients for over 30 years in assuring their facilities are fully compliant.

7. Additional expansion

When will your facility's air compression needs change? Are you planning to expand production in the near future? If so, you may consider a larger compressor now to prepare for growth. How you can finance your purchase may be something to consider

Leasing, financing a larger model, and spreading the expense over time may make getting the compressor you need in the future for what you can afford now easier than you thought. Click here for more information about financing options.

Learn more about our range of compressors from Elgi, or contact us to help you select the compressor to best meet your needs.