Air compressors are devices powered by either an electric motor or a diesel engine. Their role is to deliver compressed air. The compressed air is then used to power a wide range of tools, equipment, and machines across various industries.
There are several different types of air compressors, ranging from small portable units to industrial machines, each offering numerous benefits across industries. The air compressor benefits include increased efficiency, safe power sources, low power consumption, and they are also cost-effective.
In this informative guide, we’ll learn how air compressors operate and their various applications across the leading industries.
A] What Is The Working Principle Of Air Compressor?
The working principle of air compressor involves the conversion of power into compressed air. The conversion process reduces the volume of air and increases its pressure. The air compressor components include a motor or engine, an air intake valve, a compression chamber, and a storage tank.
When the motor or engine of the air compressor is switched on, it powers the compression chamber, which draws in air through the intake valve. As the piston or other compressing device moves inside the chamber, the volume of air is reduced, which increases its pressure.
The compressed air is then stored in a tank, where it can be used for numerous applications, such as powering pneumatic tools or operating assembly line machinery. The pressure of the compressed air is automatically regulated with a pressure switch. A pressure switch turns off the motor or engine when the required pressure is reached and turns it back on when the pressure falls below a certain level.
While traditional air compressors didn’t have pressure switches, modern compressors have made this addition as it improves the durability of the product and also makes it safe to operate. Some air compressors may also have additional components, such as filters and separators, to remove moisture and impurities from the compressed air before it is used.
In this section we have answered the question, how does a compressor work. To understand how different types of air compressors work at their base level, you can refer to our guide sharing the working principle of screw compressor. It will give you an understanding of how the working of screw compressors differs.
B] Applications Of Air Compressors Across Various Industries
Air compressors have a wide range of applications across various industries. Listed below are some of the common applications of air compressors in different industries:
1. Auto Industry
In the auto industry, air compressors are used in various operations such as painting, sanding, and powering pneumatic tools such as impact wrenches and ratchets.
- Large auto manufacturing plants require rotary screw compressors since they need large volumes of air with continuous delivery.
- Smaller auto repair shops use reciprocating air compressors as they are portable and more cost-effective.
2. Chemical Industry
The chemical industry uses air compressors for various purposes including handling chemicals, pneumatic conveying, and mixing operations.
- It uses reciprocating compressors for small to medium-sized applications that require low flow and high pressures. These applications include gas boosters, pneumatic control systems, and laboratory equipment.
- It uses rotary screw compressors for large-scale applications such as chemical processing and pneumatic conveying as these require high flow and high pressure.
- Since oil-free compressors provide pure air, the chemical industry also uses oil-free compressors for the production of pharmaceuticals, foods, processing, and conductor manufacturing. This eliminates the risk of oil contamination.
3. Glass Industry
The glass industry utilises air compressors for glass cutting and polishing operations. It also uses air compressors for manufacturing glass bottles and jars.
- Small-scale glass operations use reciprocating air compressors for glass blowing and glass cutting.
- Large-scale manufacturing plants use rotary screw compressors for their high flow and high-pressure applications, such as supplying compressed air to the glass annealing furnace, operating pneumatic conveyors, and glass cutting machines.
- Manufacturing glass bottles and laboratory equipment requires pure compressed air, which can be generated with the help of oil-free compressors.
4. Pet Bottling Industry
Air compressors are used in PET bottle manufacturing for blow moulding operations. It also uses them for the filling and capping process of bottled beverages.
- Small to medium-sized pet bottling operations use reciprocating air compressors as they are ideal for low-flow and high-pressure applications such as pneumatic tools and used in filling machines for operating pneumatic valves or actuators.
- Large-scale pet bottling plants require high flow and high-pressure air produced by rotary screw compressors and are used for filling machines to operate conveyor belts or pneumatic actuators and conveying systems.
- Beverage packaging requires pure air, and therefore an oil-free compressor is used.
5. Food and Beverage Industry
The food industry uses air compressors for numerous food and beverage processing operations such as filling, mixing, and packaging.
- Oil-free air compressors are primarily used in the production of food and beverages as they eliminate the risk of oil contamination.
- Large-scale food and beverage manufacturing plants use rotary screw compressors for conveying systems, filling machines, and packaging equipment.
- Small-scale food and beverage operations use scroll compressors for low-flow and low-pressure applications such as pneumatic equipment.
- Reciprocating air compressors with low to medium flow and medium pressure are used in operating small pneumatic equipment and filling machines.
6. Pharmaceutical Industry
In the medical industry, air compressors are used in manufacturing drugs and medicines, especially in tablet coating, mixing, and packaging.
- Oil-free rotary screw compressors are used in laboratories, production areas, and sterile rooms where there is a need for clear compressed air.
- Scroll compressors, with their low noise levels, can be used in pharmaceutical research and development facilities and clinical laboratories.
- Reciprocating air compressors are used for packaging and filling operations.
7. Packaging Industry
The packaging industry uses air compressors for operations such as sealing, labelling, and filling.
- It uses reciprocating air compressors for operating filling and packaging machines that require intermittent compressed air delivery and high-pressure output.
- Rotary screw compressors, with their continuous supply of compressed air at constant pressure, are used for operating pneumatic conveyors.
- Oil-free compressors are used in areas where there’s a need for clean, sterile, or dry compressed air. It is used for packaging items, such as food, beverage, pharmaceutical, and electronics.
8. Shipping Industry
The shipping industry utilises air compressors for tasks such as loading and unloading cargo, powering tools, and controlling the ship’s systems.
- Reciprocating air compressors are used for powering equipment such as sanders, grinders, drills, and impact wrenches.
- Screw compressors are used for operating control systems, such as pneumatic actuators, valves, and cylinders which are crucial for ship operation, primarily for steering and propelling.
9. Textile Industry
Air compressors are used in the textile industry for tasks such as spinning, weaving, and dyeing.
- The textile industry uses reciprocating air compressors to power pneumatic tools and equipment such as looms, knitting machines and textile printing machines.
- Screw compressors are used to provide compressed air for spinning and weaving machines that require a continuous supply of compressed air.
- Oil-free compressors are used in the production of high-quality fabrics and textiles where clean, dry, and oil-free compressed air is needed.
10. Medical Industry
Air compressors are used in the medical industry for a variety of applications, which includes powering surgical equipment and breathing apparatus such as ventilators.
- Reciprocating air compressors provide clean compressed air for powering ventilators and dental tools. They are also used for sterilising medical equipment. They are also used in laboratories and research facilities for mass spectrometry and gas chromatography.
- Screw air compressors provide clean, oil-free compressed air for medical equipment and devices. They are also used for powering surgical tools, anaesthesia machines, and medical air systems.
- Scroll Oil-Free Compressors are used by both small clinics and major medical centres for tasks needing quiet operation and can benefit from low maintenance.
11. Iron and Steel Industry
In the iron and steel industry, air compressors can be used for various operations such as blasting, painting, and powering pneumatic tools.
- The iron and steel industry uses reciprocating air compressors to power pneumatic tools and equipment such as grinders, drills, and hammers.
- It uses screw compressors for powering pneumatic control systems such as actuators, valves, and cylinders, needed for steel production processes such as smelting, casting, and rolling.
- Oil-free compressors are for the production of high-quality steel products that require clean and oil-free compressed air.
Conclusion
In this guide, we have covered the working principle of air compressors and the numerous applications of different types of air compressors across different industries. These applications signify how crucial an air compressor is and how it has been powering tools, equipment, and machines across a wide range of industries.
If you’re looking for an industrial air compressor, consider investing in an air compressor from reputed air compressor suppliers. You can not only contact us for more information about our products but also refer to our guide which can help you with the buying process.