When it comes to compressed air systems, there’s a common misconception that bigger is better. However, running an oversized compressor can contribute to a host of issues that compromise both the equipment and your operational efficiency. At Focus Industrial, we recently had a new service customer reach out about a serious compressor failure, and the root cause was directly linked to oversizing.
A new customer contacted us with a major issue in their system. Their 11kW Ingersoll Rand screw compressor had unexpectedly shut down, and upon closer inspection, we identified that the compressor was significantly oversized for the application. The oversized unit had caused excessive moisture build-up inside the machine, which eventually led to rust forming on the screws.
Due to the compressor’s size, it rarely ran long enough to reach the optimal temperature needed to evaporate moisture. When a compressor is oversized, it tends to idle or run on lighter loads more frequently. This results in the compressor not heating up sufficiently to vaporise any accumulated moisture, allowing it to linger and settle inside the unit. In this case, over time, the screws rusted, which is both costly and disruptive. This customer faced unplanned downtime, and without immediate intervention, the damage could have required a full screw element replacement.
While it might seem that opting for a larger compressor will provide ample capacity, the reality is that oversizing leads to several long-term problems:
The importance of having the right-sized equipment for your operations cannot be understated. We encourage businesses to conduct thorough assessments before investing in a new compressor. This includes analysing factors like peak usage, duty cycles, and any fluctuations in operational patterns. Using tools like compressed air audits and flow metres can precisely gauge your needs and recommend the optimal solution.
Proper sizing not only prevents moisture issues and rust but also extends the life of your equipment and reduces your energy footprint. Our team offers consultations to help you navigate these decisions, ensuring you invest in a compressor that matches your needs.
If you’re concerned about whether your compressor is sized correctly, it may be time to have it evaluated. At Focus Industrial, we specialise in guiding businesses through this process, helping you avoid the costly mistakes associated with oversizing. We provide in-depth assessments and can recommend whether a fixed speed or VSD compressor option will best meet your unique air demands.
Don’t let an oversized compressor lead to rusted components, wasted energy, and unexpected repairs. Contact us today for expert guidance and to find a solution that fits your business needs. Sizing your compressor correctly is the first step to achieving a reliable, cost-effective, and efficient compressed air system that supports your long-term goals.
17-20 Altair Place, Jamisontown, NSW, 2750
1800 763 883
sales@focusindustrial.com.au
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