Why Compressed Air Quality Matters: Protecting Your Equipment and Products

After spending many years working with compressed air systems, I’ve seen firsthand how crucial proper filtration is. In various industries—from automotive to food and beverage—compressed air systems encounter several contaminants that can lead to equipment failure and compromised product quality. In this article, I'll walk you through what I've observed as the most common contaminants and how to deal with them using efficient filtration techniques.

Common contaminants in compressed air systems

Let’s start with the contaminants. The ones I most often come across are:

• Water
• Dirt and particulate matter
• Oil (both liquid and vapor)
• Hydrocarbons
• Bacteria

In most cases, these contaminants are present throughout the system, and if you don't have proper filtration in place, they can cause serious downstream issues. For more information on ensuring clean air for your equipment, visit our compressed air service page.

Water contamination: The need for air dryers

Water is the number one culprit in compressed air systems. It’s always there, and if you don’t remove it, you’ll face problems. To deal with water, the most common solution is an air dryer. Typically, we use a refrigeration air dryer, where we take compressed air at one temperature, cool it to condense moisture, and then remove the water.

However, for applications that need air with even lower moisture content, we use a desiccant dryer. This type of dryer uses materials that absorb moisture. Think of the desiccant packets you find in a new pair of shoes—the ones that say “Do not eat.” That’s the same idea but on a much larger scale, removing moisture from the air to a point where the dew point can reach -40°C or even lower, depending on the desiccant media used.

Dirt and particulate matter: Protecting equipment and products

Dirt is another common problem. To give an idea of how much dirt can be in compressed air, I often use this analogy: Imagine being in a movie theater, looking back at the projector. You see all those dust particles floating in the light beam. Now, imagine that air being compressed seven times. The amount of particulate matter in that compressed air is huge.

These particles can wreak havoc on equipment and product quality. If left unchecked, dirt in the system can damage components like air dryers, air tools, and ultimately the product itself. That’s why specialized filters are critical to remove these contaminants from the compressed air.

Oil contamination: A common industrial issue

Oil contamination is a frequent problem in compressed air systems, particularly in industries like automotive painting. If you don’t remove oil, whether it’s in liquid or vapour form, it can cause serious defects in the final product. For example, without proper filtration, oil can lead to defects like “orange peel” or “fish eyes” in the paint finish on a car. These issues occur when oil gets into the compressed air used in painting, creating imperfections that are difficult to fix.

To combat oil contamination, different types of filter such as oil removal filters and activated carbon filters are used. These filters are designed to ensure that no oil makes it downstream, ensuring a clean and smooth finish in processes where air purity is critical.

The importance of regular maintenance for filtration systems

Filtration isn’t a one-time fix. To keep your system running smoothly, regular filter maintenance is essential. In my experience, replacing filters at the right intervals can save both time and money in the long run.

Here’s what I recommend based on industry best practices:

• Pre-filters should be replaced every 12 months or every 8,000 operating hours, whichever comes first. This ensures the system remains efficient and avoids pressure drops that can increase energy consumption.
• Oil removal filters need to be changed every 3 to 6 months, especially in industries like pharmaceuticals, food, and beverage, where air quality is critical.
• Activated carbon filters should be replaced every 3 months to guarantee effective oil vapor removal.

It’s also important to regularly check the auto-drain system. If the auto-drain isn’t functioning properly, liquids like water or oil can stay in the system, leading to contamination downstream and possibly damaging your equipment.

New advancements in filtration technology

There have been significant advancements in filtration technology recently. One that stands out to me is the reintroduction of Ultrafilter into the marketplace. Ultrafilter was dormant for some years due to non-compete agreements, but now they’re back, offering top-tier filtration for industries that need sterile compressed air, like food and pharmaceuticals. Their filters are designed to be highly efficient, removing contaminants with almost 100% success. 99.99999% to be exact. “Nothing beats an ultrafilter”.

I’ve worked with Ultrafilter in several cases where sterile air was necessary, and their systems deliver on what they promise. These filters ensure that your compressed air is free of contaminants, preserving the quality of both your equipment and your product.

Conclusion: Why filtration is essential for every industry

To wrap this up, compressed air filtration is essential to maintaining both the efficiency of your equipment and the quality of your final product. Whether you're dealing with water, dirt, or oil, you need to have the right filtration systems in place. Without it, you’re setting yourself up for costly repairs, product defects, and unnecessary downtime.

I’ve seen firsthand what can happen when proper filtration isn’t used, and it’s not pretty. But with the right filters, proper maintenance, and the latest advancements in filtration technology, you can protect your equipment and ensure your operations run smoothly.Ensure your filtration systems run smoothly with our preventative maintenance services.