Big Boy Compressor?

[mimosatexas]

We are underway on a pretty huge expansion and upgrade of our facilities and equipment.  Within 90 days it looks like we will have the following equipment up and running and needing air, assuming we get all our logistical ducks in a row.

• G3 14/16
• Sportsman 8/10
• Sabre 8/10
• 2 Saturn 3040

...and a whole host of peripheral needs like blowing moisture out of screens, etc.

I know we want to go rotary screw, but beyond that does anyone have suggestions on size (considering potential future expansion as well), brand, peripherals (chillers, auxilary tanks, filters, etc?).  Any clever stuff I should add or think about that a shop shouldnt be without related to compressed air?  Thanks!

[ABuffington]

My favorite are Mattei's.  A bit pricier, but as quiet as a refrigerator. There are other similar ones I have seen but this is the brand we ended up with.  It can be sitting near your press and you won't go deaf.  I had 2 screws, a Leroy and an Ingersoll Rand and I could hear the whine of the screw from the front of a 40,000 sq ft building like a drill bit in my head.  Probably some advancements, but compare.  For some the quieter compressor allows it to be in the shop and not outside where it has to weather the elements and still be there next to the building on a Monday morning.  One thing that helps growth is to pipe with copper (No corrosion and rust from black pipe that has to be filtered out at the press.) Create a loop of 2" pipe over all of your presses with quick disconnect fittings for the air lines to the presses as well as some for an air hose for an air gun/tools to clean/fix stuff or transfer presses or other pneumatic equipment. The 2" pipe loop over the center of all presses and work areas helps balance air pressure evenly. A straight line from the compressor to the farthest press winds up starving the last in line for air with other presses using up the pressure.  Holding tanks at the compressor and at the farthest point can also help maintain peak air pressure as a buffer when the weather is hot.  Compressors aren't as efficient in hot weather, so get more hp than you think you will need for growth and hot dry air days.  A good air compressor company can help you spec out the plumbing needed and horsepower.  Get 3 phase 240 to run these beasts.

[farmboygraphics]

I'm pretty happy with our Ingersol Rotary. Just made a quick video of it running in my small area. https://youtu.be/oRcW_qbDKU4

[Biverson]

My favorite are Mattei's.  A bit pricier, but as quiet as a refrigerator. There are other similar ones I have seen but this is the brand we ended up with.  It can be sitting near your press and you won't go deaf.  I had 2 screws, a Leroy and an Ingersoll Rand and I could hear the whine of the screw from the front of a 40,000 sq ft building like a drill bit in my head.  Probably some advancements, but compare.  For some the quieter compressor allows it to be in the shop and not outside where it has to weather the elements and still be there next to the building on a Monday morning.  One thing that helps growth is to pipe with copper (No corrosion and rust from black pipe that has to be filtered out at the press.) Create a loop of 2" pipe over all of your presses with quick disconnect fittings for the air lines to the presses as well as some for an air hose for an air gun/tools to clean/fix stuff or transfer presses or other pneumatic equipment. The 2" pipe loop over the center of all presses and work areas helps balance air pressure evenly. A straight line from the compressor to the farthest press winds up starving the last in line for air with other presses using up the pressure.  Holding tanks at the compressor and at the farthest point can also help maintain peak air pressure as a buffer when the weather is hot.  Compressors aren't as efficient in hot weather, so get more hp than you think you will need for growth and hot dry air days.  A good air compressor company can help you spec out the plumbing needed and horsepower.  Get 3 phase 240 to run these beasts.

I just got a Mattei Blade 4 5hp rotary vane in. Still need the press, but got it hooked up. Super quiet. As far as price I thought it was right in line with comparable rotary screws, if not cheaper. You'd definitely need a bigger unit than mine so maybe the higher end ones are pricier. It's also very efficient. Only 14 amps, but it's 3-phase 230V.

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[Nation03]

Polar Air has been great. They have a ton of options and can customize a setup for you to leave room for expansion down the line. 5 year no questions asked warrantee and the support has been stellar thus far. 

[ericheartsu]

we have 2 Atlas copco screw compressors. We can cycle between them, and also if one is down, we have the other we can rely on.

You should also look into Variable speed compressors. or VSD. pretty cool.

[Jepaul]

We put in two Kaeser SFC 410.  They put out 2500cfm at 125psi.   The variable speeds will save us 20-25% on electric.  They each have 550hp motors so that savings is significant.  The SFC line of compressors is IMO the best compressor you can buy for a manufacturing operation that needs clean dry air at a stable 125psi with a tolerance of 1%.


https://us.kaeser.com/download.ashx?id=tcm:46-37648

[inkman996]

Just watched this video the other day, we bought two brand new Fusion IQ heat presses and I need to run air to them from one end of the building to the other and searching for some good info on how to best do it I came across this video and it is really great for a shop like what you need.

https://www.youtube.com/watch?v=T2soRICBvRg

[Zelko-4-EVA]

we have an Atlas Copco GA-18VSD - works great for our 5 presses, folding machine, three heat presses, two pad printers, 4 air guns, stretching tables and a pretreat machine.

i have it connected to 200 gallons or so of storage - two air tanks - one wet (before the air dryer) and one dry.  air dryer, oil separator, filters - i have the shop on 1" copper and the pipe on a loop.

all the air intakes have furnace filters - keeps the radiators from accumulating lint.

my advice - get more storage than you think you need - minimum of 1 gallon of storage per CFM used, more is better.  get an air chiller that is twice the capacity of the compressor.  automatic condensate drains will help keep it automated so you wont have to drain the water manually.   a variable speed compressor will cost a bit more up front, but the electricity savings will pay for the added cost.  if you are putting in the pipe, add a couple of drops for the future, its easier to put it in now.

[ebscreen]

we have an Atlas Copco GA-18VSD - works great for our 5 presses, folding machine, three heat presses, two pad printers, 4 air guns, stretching tables and a pretreat machine.

i have it connected to 200 gallons or so of storage - two air tanks - one wet (before the air dryer) and one dry.  air dryer, oil separator, filters - i have the shop on 1" copper and the pipe on a loop.

all the air intakes have furnace filters - keeps the radiators from accumulating lint.

my advice - get more storage than you think you need - minimum of 1 gallon of storage per CFM used, more is better.  get an air chiller that is twice the capacity of the compressor.  automatic condensate drains will help keep it automated so you wont have to drain the water manually.   a variable speed compressor will cost a bit more up front, but the electricity savings will pay for the added cost.  if you are putting in the pipe, add a couple of drops for the future, its easier to put it in now.

This is the way to go, especially with separate receivers and auto-drains. I will only add that you will need a way to drain condensate from the tanks/chiller, so locating near a drain is ideal, a condensate pump second option. The "don't forget to dump the bucket daily" doesn't work out in the long run.

Also valve everything, be able to isolate/bypass any branch or component of the system.

[Admiral]

I went with a 25hp Atlas Copco, dryer built in, tank on bottom.  Our backup is a 15hp Chicago (Atlas Copco rebrand) that I bought used.  It also has built in dryer.

One funny point is the 25hp I bought new dries the air before the tank, which I think is pretty smart.  I chose not to go the VSD because the extra cost would take 3+ years to payoff and we wanted to run lean.  VSD is more important on larger air compressors imo anyway, like a 40hp one.

It sounds like a 20hp would do well with your list.  Do you have room to grow beyond that? is it going to be 30% more equipment? 50% more? not really?

I would do a 20hp Kaeser with dryer.  Then a separate tank after, filters after that.

I used AirPipe aluminum piping, 1" in most of a loop in the main barn which uses 70% of our air supply, then off shoots to other parts of the warehouse running other equipment.  Very easy to run your own aluminum air pipe and it's cleaner and has less pressure drop than black iron pipe.