Don’t run from the inevitable. All air compressors have a lifespan. Maybe you think that you’re saving money by holding on to that old air compressor unit. And since you’ve been consistent with maintenance you figure it’s good for a few more years. This is a very common mistake and we’ve seen it time and again with our first-time clients. In this article, we’re going to explain to you why you’re probably incurring extra costs by not upgrading your air compressor unit.
Air compressor upgrade
Compressed air is an essential component in any modern manufacturing facility, and it is often referred to as the 4th utility.
Having a reliable source of compressed air is critical. As plant efficiency and profitability take centre stage many facilities have just enough compressors to meet the plant demand. Like any other plant utility, a good maintenance regime needs to be followed to maximize availability. But as the compressor units start ageing it’s important to plan for a timely replacement. Otherwise, an unexpected failure could trigger production delays, leading to lost revenue and profit.
Compressors typically have an average life span of 10-15 years considering the harsh climate conditions that prevail in India. Typically, a user should start thinking of compressor replacement from the 7th year onward depending upon the running hours within each year as the unit approaches the time for an overhaul. Ageing also impacts some of the major compressor components such as the motor, the coolers and the compressor element itself. This has a negative impact on efficiency and increases the risk of sudden failure.
Facts to consider for replacement
Are you aware that energy or power contributes up to 80% of the total life cycle cost of an air compressor?
If the impact of aging-related energy loss is accounted for, coupled with the fact that newer generation compressors are more efficient, it would be worth investigating the option of replacement much sooner. And if the risk of breakdown and the impact of delayed production is factored in it becomes apparent that it is wiser to replace rather than repair.
Compressors, like all other equipment that operate continuously around the clock, have an escalating maintenance cost linked to aging. This escalating maintenance cost is easily saved by investing in a newer compressor.
In addition to this, an ageing compressor loses efficiency, and this efficiency loss increases as the compressor start reaching its due overhaul. Even after overhaul, the compressor might not reach its peak efficiency like a new unit.
However, before making your decision it’s best to check the condition of your compressors for energy consumption & operational efficiency.
Vision Air Technologies audit gives you the answer
A Vision Air Technologies audit provides a comprehensive assessment of your compressed air system and its performance. Our specialists visit your compressor room and use advanced data loggers to collect the information needed to evaluate system efficiency and energy consumption.
The data loggers are connected to the air compressor for 7–14 days to monitor operating trends and demand fluctuations during both weekdays and weekends.
The audit results offer a clear picture of your actual compressed air usage over time, helping you identify demand peaks, consumption patterns, and opportunities to improve efficiency, reduce energy costs, and plan equipment upgrades with confidence.