#oilfreescrewcompressors

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ELGI AB - Oil Free Screw Air Compressor - ELGi India

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ELGi is one of the very few compressor companies to design and manufacture airends for Oil free air compressor technology. Our new AB series compressors provide disruptive benefits in terms of efficiency, reliability and air quality resulting in lower life cycle cost and high uptime.

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AS Equipment - Air Accessories & Compressor Spare Parts Dealers.  We offer a wide range of competitively priced air accessories products, including air compressor spare parts, piston, and a portable compressor. http://www.asequipment.in/air-accessories.html

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Electric Lubricated Screw Compressors

ELGi USA is a global player and a leading manufacturer of Electric Screw Compressors - Assures your business up and running with UPTIME promise.

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Oil-Free Piston Air Compressors | Oil-Free Reciprocating Compressor

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Making Screw Air Compressors Oil-free

It might be hard to believe but air compressors have been around for thousands of years. The earliest known compressors were bellows, used to blow compressed air into furnaces to stoke up the heat, thereby allowing ancient men to produce stronger and better metals for tools and weapons. >

Following the invention of steam engines, they became a popular method to power air compressors. Subsequently, Internal Combustion (IC) engines began to be used as a power source for operating reciprocating air compressors. Later, as larger industries were established, they demanded more efficient compressors capable of running with minimal maintenance and for longer periods. A rotary air compressor was the answer. Both these types of compressors continued to evolve over time and today, they are both highly efficient and technologically well advanced. Conventional reciprocating air compressors though have certain innate limitations; most notable being that the oil used for lubrication is carried along with the compressed air. Filtering removes much of the oil but not all of it. For example; pre-filters, high efficiency coalescing filters and activated carbon filters remove trapped oil to a great extent.

Oil-free compressed air solutions are used extensively in the pharmaceutical, textile & automotive industries.

 But these filters themselves have characteristic limitations. For instance, above 20°C, coalescing filters do not remove fine oil vapours, leaving very fine particles of residual oil in the form of aerosols; and activated carbon filters are not usable at filtration temperatures above 40ºC because the carbon then absorbs the oil vapour, gets saturated, and becomes ineffective. And, filtration itself raises another problem: safe disposal of used filters to avoid environmental contamination. Notwithstanding the environmental issue however, there are several industrial applications that require compressed air that is completely oil-free. Food and beverage, pharmaceuticals, electronics, automotive painting, textiles, paper and cosmetics are typical examples. These applications demand wide operating temperatures of 0-45°C, stringent air purity standards higher than ISO 8573-Class I, high levels of safety, eco-friendly operation and some more. Even the most advanced filtration technology falls short of meeting such exceptional standards of air purity.

Plainly, lubricated compressors were not the answer. It required a radically new technology of air compression. Enter oil-free screw air compressors.

ELGi’s Screw Compressors are designed to save energy and ensure long life.

This inventive machine uses no lubricating oil in the compression chamber and hence delivers compressed air with practically no trace of oil. Additionally, because of the continuous sweeping motion of the screws – two meshing helical screws known as rotors, driven by a pair of timing gears – there is very little pulsation or surging of flow, which occurs with piston compressors. Screw compressors thus deliver smooth, pulse-free compressed air. They also tend to be compact and run smoothly with minimal vibration. Since they also employ a more efficient compression system, they not only reduce energy costs but also enable precise adaptation to end-user requirements based on careful study and analysis of their critical processes and customising with a controlled, total compressed air system, thereby also improving productivity.

Despite all its apparent advantages, oil-free screw air compressors continued to face technological and manufacturing challenges, especially pertaining to the problem of overheating due to the absence of lubricating oil in the compressor chamber. Furthermore, despite being oil-free, there was still the need for filtration as hydrocarbons and other contaminants ingested from the ambient air required to be removed prior to the point-of-use. All this began to affect their popularity to some extent. However, this also prompted a new development: oil began to be injected into the compression cavities to not only aid sealing but also provide a cooling sink for the heat of compression.

In this so-called ‘oil-flooded’ rotary screw compressor, the oil was then separated from the compressed air, cooled, filtered and recycled. The injected oil not only helped in lowering the compression temperature but also captured extraneous particulates from the incoming air, thus effectively reducing the particle loading of subsequent air filtration. Having thus overcome the initial problems that oil-free compressors faced, there was a shift from oil-free to oil-flooded compressors, which then gained popularity.

Oil-Free Two Stage: Air-Cooled Model

But the need for a completely oil-free compressor remained. This was felt keenly in industrial applications where even traces of oil in processed air could be disastrous. For instance, even minute particles of oil in precision electronic circuitry or critical semiconductor components can play havoc with electronic gadgets. Lube oil traces in processed food and beverages mean serious health risks. Pharmaceutical applications demand pristine air too. It is the same with paper mills, textiles, high-gloss painting of automobiles and many others. While Western countries had strict regulations governing the purity of air used in such critical applications, Asian countries including India and China had less stringent rules. But it was only a question of time before they too fell in line. And, although industries continued to rely on filtration to get rid of the entrapped oil, complex filtration equipment added to the cost, created air pressure drops and still did not deliver 100% oil-free air. At ELGi, this presented a situation ripe with potential.

Oil-Free Two Stage: Water-Cooled Model

ELGi embarked on developing the oil-free screw air compressor by obviating the need for oil as a medium to carry away the heat of compression. By early 2005, the first prototype was assembled and tested. And by early 2008, a test compressor was commissioned at a user’s facility for validation. Next year five more were commissioned at different locations. These models completed 10,000 hours of validation. Regular sales began by early 2011. Today, ELGi’s in-house oil-free technology with inter-cooler has been validated in demanding industrial applications for over 150,000 cumulative hours.

Inside the ELGi factory

The fully-packaged ELGi-NE series has models with high volumetric efficiency that deliver from 500 to 1800 cfm (cubic feet per minute) and pressures of up to 10 bars (kg/cm2.) Incorporating superior safety norms, these models not only have low energy losses and low air outlet temperatures but are also energy efficient and compact.

They employ two-stage compression with external water jacket inter-cooling, a unique eta-V profile rotor enabling high swept volume, low operating noise and low vibration achieved by combining radial roller bearings and 4-point axially loaded ball bearings. Innovative features like carbon impregnated SS air seals, helical grooved non-contact bronze oil seals and high-performance Visco-seals at suction and discharge rotor ends, an ingenious process of PTFE and PFA (Teflon) dry lubricant coating on carbon steel rotors, an efficient helix-angled timing gear and robustly designed cupro-nickel intercooler and after cooler, heat exchangers offering superior corrosion resistance and finally optimally designed capacity control valves; all ensure not just high efficiency but safety, durability, easy maintenance and low operating cost.

Compression is also very efficient on account of the precise clearances maintained between the helical rotors and the compression chamber, thanks to the unique eta-V profiles designed by ELGi. This rotor design reduces pressure losses and increases stage efficiencies, leading to an overall increase in adiabatic efficiency.

ELGi builds its own rotor milling machines to ensure quality rotors with lowest manufacturing cost.

Only a handful of companies in the world have this design capability. It is to be noted however, that though the machine is termed an oil-free screw compressor, it applies to only the screw chamber that forms the air compression cavity. Oil is nevertheless used in the machine – to lubricate a slew of components like the capacity control valves, air-end bearings, the timing gears and the air-end stage gear. So even though the rotors and the screw chamber do not use any lubricating oil, there is nevertheless an oil circuit comprising the oil pump, cooler, filter and oil sump. Similarly, there is also a water circuit that supplies cooling water to the intercooler, after cooler, and the 1st and 2nd stage air-ends. For ELGi, this development has been a rewarding experience. Industry watchers have it that globally, ELGi is one of only 5 corporate companies to design and manufacture oil-free air-ends.

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Skid Mounted Air Compressors - 185 to 1500 CFM - ELGi

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How to choose the right piston air compressor? (Belt Drive or Direct Drive)

Irrespective of the technology, choosing the right compressor for your application is very critical. This will optimise the performance and save money in terms of energy, maintenance and service.

With piston compressors, there are two alternatives – belt drive and direct drive. To make the right choice for your compressed air needs, it is important to understand the difference between the two.

Understanding the requirement

The requirement for any given application will play a big role while deciding on the type of the piston compressor - belt drive or direct drive.

The factors to be considered are as follows:

Pressure and Flow

Duty Cycle and duration of use

Environment

Maintenance

Energy efficiency

The Technology

Belt driven reciprocating compressors are conventional machines, proven for their durability in intermittent usage patterns over the years. On the other hand, direct drive machines are quieter, compact and suit a higher duty cycle with proven reliability when compared to a belt drive.

Please do note that both differ in terms of the “use case” they fit into.

Belt Drive Reciprocating Air Compressor

A belt drive reciprocating air compressor has a belt that connects the motor and the pump. When the motor runs, the belt transfers the power through pulleys to run the pump.

The energy and maintenance costs of these machines are comparatively higher, owing to the transmission system and higher number of touchpoints.

This is why, a periodic check of the pulley’s alignment and the belt tension is required. Improper alignment will impact the motor’s load pattern, thereby increasing the energy cost. This can also result in belt failure due to excessive tension.

Direct Drive Reciprocating Air Compressor

A direct drive reciprocating air compressor has a crankshaft that is directly connected to the motor, thereby eliminating transmission losses.

Energy Efficient: Since the crankshaft is directly connected to the motor, there is no need to replace the conventional belt drive. As a result, the loss in energy due to the transmission is eradicated.

Minimum Maintenance Cost: Direct drive air compressors have fewer components than belt drive compressors. This is why, they do not require as many part replacements resulting from wear-and-tear.

Lesser Noise: Elimination of belts and pulleys makes the direct drive operate “quietly” as compared to its belt drive counterpart. This is why, they are generally better for environments where noise emissions have to be kept low, such as indoors or residential neighbourhoods.

Compact: As the drive and driven are integrated, the compact arrangement of the machine is an added advantage.

Belt drive or direct drive – What to choose?

If you use compressed air for longer hours and want to keep your energy costs low, then a direct drive model, such as ELGi’s LD Series, is the right choice. In addition to the inherent benefits of the direct drive technology, the LD series also offers more superior value additions such as:

Higher energy efficiency: Apart from ensuring savings due to elimination of transmission losses, ELGi’s direct drive compressors offer

best-in-class flow as compared to any piston compressor in the market, thereby offering higher flow per HP

Eco friendly and minimum maintenance cost: ELGi’s direct drive compressors are assured with the lowest oil fill requirement

Silent: The noise levels of such systems are close to screw compressors

Compact: These piston compressors can fit anywhere with proper ventilation

Flexible: They have a duplex system, which supports varying industry demand, especially in the 10 and 15 HP variants

Reliable: ELGi’s proven parts and robust materials ensure reliability. What’s more, they are backed by ELGi’s Pan India Service support

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Portable Air Compressors - Diesel & Electric Powered - ELGI India

ELGi makes reliable & rugged portable air compressors, available in single and two-stage models designed for all industrial applications.

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ELECTRIC LUBRICATED SCREW AIR COMPRESSOR

EN SERIES SCREW COMPRESSORS 2.2-45 KW

ELGi’s EN Series oil lubricated screw air compressors are known for their reliability, low maintenance requirements, compact design, and small footprint, making them ideal for industrial applications where size, efficiency, and cost matter.

Elgi Equipments Limited, Elgi Industrial Complex, Trichy Road, Singanallur, Coimbatore – 641005

Tel : 0422 2589555 Fax : +91-422-2573697 Toll Free (India) : 1800-425-3544 1800-203-3544 Email : enquiry@elgi.com

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What to Look for in a Reliable Air Compressor Manufacturer?

What to Look for in a Reliable Air Compressor Manufacturer?

When you're in the market for an air compressor, it's essential to recognize that a reliable air compressor manufacturer should offer much more than just the sale of a machine. Choosing the right supplier can make all the difference. A dependable supplier goes beyond offering an air compressor; they provide you with efficient and reliable equipment, a wide array of options to choose from, and essential services to ensure that your air compressor operates at peak efficiency. This blog delves into the critical factors to consider when selecting an air compressor manufacturer, highlighting the significance of a holistic approach to compressed air solutions.

Choosing A Manufacturer Who Guides You

A reputable air compressor manufacturer should guide you in selecting the ideal air compressor out of many options. With numerous types of compressors available, from reciprocating / piston to rotary screw, oil-free to oil-flooded varieties, it's important to align your choice with your specific industry and application needs. The best suppliers understand this and are dedicated to meeting your unique requirements.

As an air compressor manufacturer headquartered in India, ELGi offers guidance in this decision-making process and ensures that you make a well-informed choice, perfectly suited to your needs

Warranties and Services

Warranties and services play a significant role in the reliability of an air compressor manufacturer. The best suppliers provide warranties that protect your investment, offering peace of mind. Compressor systems can be costly to repair, so these warranties can save you a substantial amount of money in the long run. Moreover, a supplier that offers service and maintenance plans ensures that you never have to worry about unexpected shutdowns due to improper maintenance. These services not only keep your equipment in optimal condition but also extend its lifespan.

Parts and Replacement

A reliable air compressor manufacturer understands that parts in a compressed air system can wear out over time. Quick access to replacement parts is essential to prevent costly downtime. Suppliers should offer efficient solutions to replace these parts, either through their service or by providing guidance to your maintenance team regarding when and how to replace components.

Using genuine ELGi parts makes your compressor last longer and work better. With our strong after-sales support, you can get ELGi compressor parts for warranty replacements and repairs quickly and hassle-free.

Providing Systems

An air compressor manufacturer should acknowledge that compressed air systems are more than just air compressors. They consist of various components, including filtration, moisture control, and other equipment that complements the air compressor to improve overall efficiency and prevent unplanned shutdowns. A reputable supplier will be well-versed in these systems and offer additional equipment that enhances the efficiency of your air compressor, ultimately improving your operations.

Customized Compressed Air

Recognizing that each industry and application has unique requirements, a reliable air compressor manufacturer should offer customized compressed air solutions. Customization ensures that your air compressor machine is tailored to meet your specific needs, improving overall efficiency and cost-effectiveness. This tailored approach to compressed air solutions sets the best suppliers apart.

ELGi excels in providing tailored solutions to meet the needs of various industries, setting them apart as a trusted compressor manufacturer in India and worldwide.

Certifications and Standards

Adherence to certifications and standards is non-negotiable when it comes to sensitive industries like pharmaceuticals, textiles, etc. When selecting an air compressor manufacturer, look for certifications such as ISO 9001 for quality management, ISO 14001 for environmental management, and ASME certification for pressure vessel safety. These certifications ensure that the compressor meets industry standards, operates safely, and adheres to quality and environmental management practices

Installation and Maintenance Services

A reliable supplier should provide installation and maintenance services. While some businesses may have in-house teams for these tasks, many do not. Suppliers that offer these services demonstrate their commitment to ensuring that your compressor project is efficient and successful. They take care of every aspect of the installation process, ensuring that the industrial air compressor is correctly set up and maintained to prevent costly disruptions.

ELGi offers an annual maintenance check to keep your compressor in top shape, reducing energy costs and maintenance expenses. Our dedicated customer care ensures your specific needs are met. Enhance the lifespan and performance of your ELGi air compressor with genuine parts. Choose from our air care plans and annual maintenance subscriptions for peak performance and increased productivity.

Conclusion

Choosing a dependable air compressor manufacturer is crucial in ensuring the efficiency and reliability of your industrial operations. ELGi offers guidance in selecting the right air compressors for industrial use, provides warranties and service plans, ensures quick access to replacement parts, offers customized solutions, adheres to industry certifications and standards, and provides installation and maintenance services. By considering these factors, you can make an informed choice that elevates your industrial operations to new heights, ultimately enhancing productivity and reducing operational costs.

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Air Compressor Manufacturer | ELGi Air Compressor India