Base Compressor Size on CFM, not HP
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The first step in choosing the proper compressor is finding the CFM demand your plant requires. CFM (Cubic Feet per Minute) describes the volume flow rate of compressed air. Improperly sizing your compressor can cost thousands of dollars in wasted electricity if you select an oversized compressor.
On the other hand, if you had more demand than you originally thought, the new compressor that you just purchased may be insufficient. Accurately determining your CFM demands is a critical first step in selecting an air compressor. Engineers work hard to improve the efficiency of air compressors and the design to produce more air than previous generations. If you are replacing an existing compressor, check your CFM rating and choose a new compressor with the same CFM rating.
Imagine you are driving your car on a hot day. Your dashboard indicates you are low on oil and need an oil change. Your engine is running hot. You change the oil, which gets filtered through your car engine and cools the vehicle down. The car runs smoother because the oil is lubricating the engine and making everything run more efficiently and reliably.
Now think of a rectangular air compressor device, about six feet high and five feet wide, inside a furniture manufacturing facility. Using oil to lubricate the air compressor motor within that facility will make the manufacturing process run efficiently and smoothly. The air, which gets hot when compressed, won’t overheat because the oil will keep it cool. The compressor will function well because the oil will keep the engine lubricated and running efficiently so the furniture-making process progresses accurately and efficiently while minimizing energy consumption and accelerates the manufacturing environment.
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This is an example of an oil-injected air compressor application! These machines are absolutely essential in powering a large variety of applications and industries - many of which wouldn't function without oil-injected compressors.
In more technical terms, oil-injected air compressors (also known as oil-flooded or oil-lubricated compressors), are compressors that use oil to lubricate the air compression chamber, lubricate parts, and seal in the air. In this device, a liquid is injected into the compression chamber and often into the compressor bearings. Its function is to cool and lubricate the compressor element's moving parts and the air being compressed internally. The compressor also reduces return leakage to the inlet. Oil is the most commonly injected liquid due to its effective lubricating and sealing properties. If the oil gets too hot, the substance gets funneled to a cooler within the compressor.
Air purity is critical for many applications where even the tiniest drop of oil, or air contaminated with oil can cause product spoilage, product recall or damage production equipment. Your specific application will determine which type of air compressor is best for you to use in your facility.
In instances where the threat & consequences of oil contamination are too high, like medical procedures, having an oil-free air compressor is a must. In applications where the consequences of oil contamination are not as great, such as general manufacturing & in industrial and small workshops, oil-injected air compressors are used.
Key takeaway: Oil-free air compressors are not necessarily “better” than oil-lubricated compressors. The compressor you choose depends on your specific application requirements and the air quality that you need to achieve!