Tips to Lengthen the Unload Cycle on an Industrial Air Compressor

Air Quality

• Cold air is denser (more compressed) than warm air. Moisture, dirt and particles make the air harder to compress. Using proper air filters and a moisture separator helps keep the air at a constant. Along with draining the lines and tank of condensation, set up the air intake in an area that is clean and has the same temperature as the rest of the system.
  
  

Air Leaks

• Air leaks are a big problem for all compressed air systems. Pipe joints, valves, gauges even the pipes themselves can all leak over time. With each air leak you are steadily draining the air tanks, which reduces the pressure and puts the system into an unloaded state. Start a regular maintenance schedule to check the entire system for leaks and repair them. Start your check with the compressor because a problem there affects the rest of the system.
  
  

Pipes and Valves

• The size of the pipes and fittings plays a large roll in air loss. Undersized pipes can cause pressure loss. The length of pipe is also a factor. For every 100 feet of pipe you can expect to loose 1 pound pressure. Valves, elbows and T-sections all add to pressure loss in the line. It's called "increased frictional air loss." The reduced pressure will seem like reduced unload time and have the compressor working overtime.
  
  

Tank Size

• Increasing the unload cycle can be as easy as installing a larger air tank. If you run 75 psi on your system and use a 10-gallon tank you will run out of air quickly. Larger tanks not only hold more air, they can withstand higher pressures. Higher pressure means more air in the tank and a longer unload cycle for your compressor. Find out what your compressor can handle, and get an air tank to suit your needs.
  
  

Equipment Maintenance

• Keep your equipment clean and in good working order. Moisture in the lines causes rust that can slow your equipment down. This means more air is needed to power the equipment. Oil each device that is using the compressed air as instructed by the manufacturer. Pressure regulator valves should be installed to regulate pressure for optimal efficiency.