Editor's Note: This post was originally published in and has been updated for accuracy, comprehensiveness, and new information.
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Sizing a new air compressor can be a difficult task. It requires a thorough knowledge of the pressure and flow needed for the application, a solid understanding of how frequently jobs are performed & how many jobs are being completed at once, and the ability to plan for upcoming changes in the application or in upcoming business needs. This may seem like a substantial amount of work; however, the benefits of correctly sizing your compressor are multifold and include improving your business' productivity, decreasing existing compressor room inefficiencies, and improving your bottom line.
Keep in mind that sizing your compressor doesn't necessarily mean the physical size of the compressor. Rather, this idea refers to making sure that your compressed air system is sized to deliver the air your production needs across your entire compressed air demand profile at peak efficiency. Many new air compressor technologies today are incredibly energy efficient and can provide the ideal flow and pressure in a smaller compressor package.
Wait - How Do I Know if My Current Industrial Compressor is Sized Correctly?
First, let's address your current air compressor system. Do you know if your current compressor is sized correctly, or is it undersized or oversized? To help you determine this, we highlight a few common signs that indicates your compressor may be undersized or oversized for the application(s) it powers:
Undersized Compressor. If your compressor is undersized, it's likely running at all times! Keep in mind that this can be a bit difficult to distinguish with rotary compressors, as they are intended to run virtually 24/7. However, this would be noticed right away with piston compressors, as they aren't intended to run 24/7. So, if you're experiencing pressure drops and the inability to complete a task (as in the application can't be completed due to the lack of compressed air supply), chances are that an undersized compressor is the issue.
Oversized Compressor. Is your compressor constantly stopping and starting (commonly known as loading and unloading)? It could be oversized! This means that your compressor will start-up, immediately meet the demand, and then stop; it then realizes that demand is present and will start-up again. This will lead to huge energy bills, largely caused by the spike in energy produced when the compressor starts up. The excessive start/stop cycle can also result in motor burnout, future mechanical problems and potential failure of the compressor.
How Do I Correctly Size a New Industrial Compressor System?
There are a few key steps to take in order to appropriately size a new industrial air compressor:
- Know Your Flow (CFM). The CFM, or flow rate of your compressor, is application-dependent, which means that having a good understanding of your plant's demand profile is critical to sizing a compressor and uncovering any potential energy efficiency opportunities. If you are trying to determine the flow requirements for a new plant, be sure to have accurate flow requirements for all equipment and estimates for the duty cycle of that equipment. For an existing operation, we recommend reaching out to a local compressed air expert to assist with this calculation. Your local expert can also guide you through planning for future expansion and make sure your air flow and quality are appropriate for your applications. Learn more about CFM, ACFM, ICFM, and SCFM here.
- Know Your Pressure (PSI). Pressure is measured in PSI, or pounds per square inch, and refers to the amount of pressure required by the tools/equipment used by your application. This is typically between 90 and 100 PSI but can also be higher or lower. While you may want to add a little padding to this pressure so that your new machine can handle any extra requirements that may be throw its way, be wary of increasing the pressure beyond what is absolutely necessary. Increased pressure means increased power bills and loss due to unregulated uses.
Learn more about PSI, PSIA, and PSIG here.
- Check Your Voltage & Phase. Your industrial compressor will require a sufficient energy source to operate, so knowing the available voltage and phase of your compressor's new 'home' (whether this is inside a building out outdoors) is essential. If you're unsure, consult with an electrician! They'll be able to tell you whether the electrical supply is single-phase or three-phase, as well as the voltage.
One of the best starting places for determining new compressor specifications is by conducting a compressed air audit. Knowing your system's compressed air demand, and subsequently determining how to deliver the right amount of compressed air at the lowest cost, will help you avoid choosing a compressor that is undersized or oversized for the job that it needs to complete.
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Whether you lead a construction team or perform home repairs, air compressors are an ideal power source. Compressors use energy from pressurized air to power air tools, with the correct size compressor making all the difference in your task's efficiency, productivity, and cost-effectiveness.
It's important to assess your job requirements, including the best air pressure, airflow and duty cycle you'll need, to help you choose the right size compressor. Continue reading to learn more about compressor sizes and how to find the right one for your project.
What to Consider When Selecting an Air Compressor
Air compressors come in many sizes, but size alone does not determine how powerful they will be. For this reason, you'll need to assess your tools' air requirements to find the right size. Consider the following points to determine how big of an air compressor you need for your project:
- Required air pressure: Determine the maximum air pressure rating (PSI) needed for your tools and equipment. A smaller PSI might be suitable for general-purpose tools, while a larger PSI might be used for demanding applications like sandblasting.
- Airflow: Before considering the correct physical size of the air compressor, assess how much air it delivers, measured in cubic feet per minute (CFM). Look at the CFM rating for the most demanding tool you use, which typically ranges between 10 and 110. To determine the correct air compressor size, consider the highest-value air pressure and air delivery requirements of your tools. Choose an air compressor that exceeds the air pressure value by 1.5 to get the correct CFM for optimal, safe use.
- Duty cycle: An air compressor's duty cycle is the amount of time it can run without overheating, often expressed as a percentage. For example, a 100% duty cycle means the compressor will deliver consistent CFM and PSI while you're using it. You'll need a higher CFM rating if you don't want to stop running the compressor regularly.
- Portability: Decide whether you'll need a portable or stationary compressor for your specific job requirements. While a stationary air compressor will have a higher CFM for heavy-duty applications, a portable one offers greater flexibility, allowing you to easily move around job sites.
- Physical dimensions and storage space: When choosing the right size compressor for air tools, consider the amount of storage space you have and the size of the tank on the compressor. You'll also need to keep a few feet of space around the compressor when using it for proper airflow.
- Power source: Determine if an electric, diesel, or gas-powered compressor is more suitable for your task. Electric motors are often more affordable and require less maintenance, while gas air compressors can be better for flexibility and portability.
Compressor Sizes and Capacities
To select the right air compressor capacity and size, consider the following CFM ratings. Note that your air tools' CFM and PSI ratings will impact how quickly the compressed air is consumed. Larger air tools will use more air and deplete the tank supply faster.
- Small-scale compressors (1-5 CFM): Smaller compressors are ideal for light-duty tasks like small airbrushing jobs, inflating tires, or operating pneumatic nail guns.
- Medium-scale compressors (6-20 CFM): A medium-scale compressor is best suited for tasks like roofing, framing, or powering paint sprayers.
- Large-scale compressors (20+ CFM): These compressors are ideal for heavy-duty tasks like sandblasting, industrial painting, powering machinery in industrial settings, and operating large pneumatic tools like rock drills, jackhammers, and large impact wrenches.
These sizes and capacities offer a general guideline for selecting an air compressor based on your task and the requirements of the tools you're using. Match the compressor size to your specific job demands for efficient operation, and choose a compressor that exceeds the rating on your strongest air tool. If you'll be running many tools at once, add their CFM ratings to find the correct size compressor.
Air Compressor Sizes for Common Tools
Air compressors have a variety of uses and are ideal for construction, automotive and industrial applications. For example, construction projects will require a compressor size that matches the demands of staplers, pneumatic nail guns and smaller air tools.
In industrial settings, larger compressors are useful for jobs like sandblasting and spray painting. Automotive workshops will require compressors that meet the needs of impact wrenches, paint sprayers and inflating tires.
Common compressor sizes for air tools include:
- Brad nailer: A small-scale compressor, such as 1-2 CFM and 70-90 PSI, is best for Brad nailers. The compressor is suitable for intermittent use in woodworking and trim work.
- Finish nailer: For finish nailers, choose an air compressor around 1 to 2.5 CFM and 70-120 PSI. Depending on how often you use it and the specific nail size, you might use a small- to medium-scale compressor.
- Staple gun: A staple gun can be operated by small-scale compressors around 1-5 CFM for light-duty upholstery and carpentry jobs.
- Impact wrench: This tool often requires a medium-scale compressor of around 6-20 CFM when used for automotive work, construction, and heavy-duty fastening tasks.
- Paint sprayer: The right air compressor size for painting will be around 8-12 CFM. It will offer consistent, smooth painting for many jobs, such as automotive projects.
- Spray gun: While you may find air spray guns with a rating lower than 10 CFM, it's best to choose a compressor that is at least 12 CFM. You might use a higher CFM depending on the torque requirements and how long you intend to use it. For instance, professional-grade finishes in woodworking or automotive painting would require a large-scale compressor of over 20 CFM.
- Sandblaster: The typical air compressor size for sandblasting is around 18-35 CFM. An industrial sandblaster is more demanding, requiring 50-100 CFM.
Rent Air Compressors From Thompson Power Systems
The right size air compressor can help you accomplish tasks at optimal performance, boost your efficiency, and lead to higher cost savings. When choosing an air compressor, it's important to consider factors like your tools' CFM, duty cycle, air pressure, and power source.
If you're unsure about what you need for your projects, Thompson Power Systems can help you select the right portable air compressor. Our experts can help you assess your options while offering easy delivery and fast installation, so you can get the exact air compressor you require when you need it.
We offer reliable diesel, electric, and high-pressure compressed air rental solutions for many tasks, no matter how complex or urgent. Contact us today to rent an air compressor or locate your nearest representative for an in-person appointment.
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