Oil-Free Air and its Uses
Oil-free compressed air is crucial in industries where the quality of air affects product quality and production, like Pharmaceuticals, Food and Beverage, Electronics, and more.
Atlas Copco Rental has the right solution for you. With our TÜV Class Zero certification under ISO 8573-1, you can have peace of mind. We guarantee 100% oil-free compressed air, not just technically oil-free (we explain this later).
For example, in the electronics industry, keeping production areas ultra-clean is crucial for quality control.
- An oil-free air compressor can operate control valvesand actuators in a production process (pressing and placing components).
- The compressed air quality must be high and free of oil and impurities to ensure smooth operation and clean contact with electronic parts.
- For tasks like cleaning and polishing printed circuit boards (PCBs), using compressors free of oil is essential to prevent air contamination and product malfunctions.
Why is High-Quality Air Important in Industry?
Protecting Industrial Equipment and Processes
First, good quality air ensures that pneumatic equipment works properly. For example, in the electronics industry, using an oil-injected air compressor or a rotary screw air compressor must be done carefully to avoid adding contaminants to the compressed air system.
Poor quality air can lead to impurities in processes involving electronic components, where even minor contamination can cause product issues.
Enhancing Industrial Efficiency
Another reason is that superior compressed air quality decreases the risk of damaging production equipment. Using oil-free air and maintaining high quality reduces the risk of contaminants like oil vapors and particles that could harm machines.
Poor oil separation and failure to manage compressor oil levels can damage equipment, requiring expensive repairs and downtime. For example, oil-lubricated compressors need regular maintenance to keep the compression chamber free of oil contaminants. Maintaining oil separators is a frequent and time-consuming task, but doing so ensures the system lasts longer.
Avoiding Product Damage
Additionally, the air used affects product quality, especially in high-risk industries like pharmaceuticals and food and beverages. Contaminated production equipment can contaminate products, making them unsafe, causing health risks, and breaking regulations. For example, in food packaging, dirty air can spoil food, leading to recalls and financial losses.
Reducing Operational Costs
Potential losses go beyond equipment and product quality. Poor quality air can increase pressure drop and reduce efficiency in the compression process, raising operational costs.
Using activated carbon filters and effective condensate treatment equipment can help maintain high-quality air by removing contaminants like oil vapors and keeping the air pure.
In short, air quality is vital to prevent contamination, protect equipment, and ensure the quality of final products in various industries. Proper maintenance, using efficient filters, and following strict air compression standards are essential to avoid operational, financial, and reputational losses.
Classes of Oil-Free Air and Their Differences
In industrial settings, oil-free air is classed based on how much oil contamination is in the compressed air. These classes are defined by the International Organization for Standardization (ISO) under the ISO 8573-1 standard. The air quality classes range from 0 to 5, with Class 0 being the cleanest and Class 5 allowing the most oil content.
- Class 0: air is the cleanest, with very strict limits for specific uses.
This class is ideal for industries needing the purest air, like pharmaceuticals, electronics, and cleanrooms.
- Class 1: air allows up to 0.01 mg/m³ of oil.
This high purity is crucial for critical applications like the food and beverage industry, where any oil could cause serious issues.
- Class 2: air permits up to 0.1 mg/m³ of oil.
This level is often used in industries where some oil is acceptable but still needs to be low, like automotive paint spraying.
- Class 3: air allows up to 1 mg/m³ of oil.
This quality is suitable for general industrial uses where small amounts of oil are tolerable, such as in pneumatic tools.
- Class 4: air can have up to 5 mg/m³ of oil.
This level is suitable for less critical applications where some oil is manageable, but good air quality is still needed.
Understanding these classes helps industries pick the best air compressors for their needs, ensuring good performance, product quality, and compliance with regulations.
Class Zero (Class 0 Oil-Free Air) Certification
Technical Oil-Free
Let's compare our Class Zero solution with the technically oil-free solution. Class Zero means no oil in the air, while 'technically oil-free' means oil is added and then filtered out.
The filtration process involves an oil separator in the oil-injected air compressor, followed by filters for oil vapor and liquid oil removal. However, this process can fail—separators can break, filters can get saturated, and high temperatures can reduce filter life. These issues increase operational risks and maintenance costs.
Why risk your business reputation? 'Technically oil-free' solutions also involve regular filter changes, condensate treatment, and higher energy costs.
Pros and Cons of Oil-Free and 'Technically Oil-Free' Air Compressors
Oil-free air compressors (Class 0)
Benefits
- Eliminate the risk of oil contamination
- Reduce maintenance costs related to oil separators
- Ensure higher compressed air quality
These compressors are critical where strict air quality class standards apply, like in the pharmaceutical, food and beverage, and electronics industries. However, oil-free compressors can be more expensive initially and may require more frequent inspections and maintenance.
Typical Applications
These air compressors are popular in industries where even small amounts of oil aerosols or oil liquids may harm products, such as pharmaceuticals, food processing, and precision electronics. They are also used in oil-free applications requiring sterile environments, like medical facilities.
'Technically oil-free' air compressors
Benefits
- Lower upfront cost
- Sometimes more efficient under certain compressed air pressure and temperature conditions
These compressors are usually oil-injected and oil-flooded air compressors, uses complex activated carbon filtration systems and coalescing filters to reduce oil vaoprs and oil particles in the air. However, there is always a risk of oil contamination, and if the filtration system fails, oil passing downstream can damage production equipment.
Typical Applications
'Technically oil-free' compressors are suitable for applications where some decrease in compressed air quality is acceptable and where budget constraints come into play. They are popular in general manufacturing, automotive services, and construction, where top air quality isn't as critical, but efficient and reliable air compression is needed.
Atlas Copco Specialty Rental Oil-Free Air Compressor Solutions
When you choose Atlas Copco Specialty Rental, you can be 100% sure that our P-range and Z-range air compressors are Class Zero TÜV certified. We offer solutions for all flow and pressure needs.
Our PTS 1600 diesel oil-free compressor has the lowest emissions on the market, with reduced NOx and PM levels. It offers high reliability and fuel efficiency, ensuring your operations run smoothly even with temporary solutions.
Our electric-driven option is also effective, eliminating harmful emissions. We provide dryers, boosters, and accessories for complete solutions. As a market leader with the largest oil-free compressor fleet in over 140 locations worldwide, we can support you anytime, anywhere, for emergencies or planned maintenance.
Contact our experts today to discuss your rental needs.
