Top 5 Reasons for Manufacturing Air Compressor Failure

Manufacturing facilities rely heavily on air compressors to keep operations running smoothly, but when they go down it can cause a severe lack of production as well as lost time and profits. With that in mind, here are the top five reasons for air compressor failure so that you can avoid air compressor problems before they start.

Air Leaks

As pipes, hoses, drains, seals and other components age, they begin to wear, crack and leak. Sometimes leaks are audible and sometimes not. It’s important to detect leaks in your pipes early yourself or have a third party check them for you with ultrasonic equipment. Leaks are, in reality, lost revenue in wasted energy expenses so you’ll also want to prevent future leaks by having employees conduct leak audits regularly and think about purchasing ultrasonic leak detection equipment if you don’t already have it.

Exceeding Pressure Limits

Running compressors at the required pressure is key to maintaining them. Running them at higher pressures increases the workload on the system and can lead to failure. Exceeding pressure limits also wastes energy and increases energy costs for performing tasks.

Inappropriate Use

An easy way to eliminate failure is by identifying which processes are necessary for compressed air and which are not. If a task can be handled by low-pressure air instead, as in the case of cooling, it is better to use it instead of compressed air. This will reduce your energy consumption and reduce the workload on your compressed air system.

Clogged Air Filters

Air filters get dirty fast, so it’s important to change them as frequently as possible to get the most out of your compressor. New air filters maximize your system performance and help the compressor run as efficiently as possible. This keeps the compressor from working harder than it should and keeps your energy cost down as well.

Lack of Routine Maintenance

It’s crucial to have a routine maintenance schedule for your system to check for problems and imperfections before they end up costing you additional time and money. In addition, everyday maintenance like turning the compressor off and making sure valves are closed when not in use will add to the life of your compressor and do the all-important job of saving you money down the road.


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