Oil Versus Oil-Free Air Compressors Guide

Air compressors are essential for powering tools and machinery in our industries. As such, you must make an informed decision when selecting your next air compressor. There is a key factor to consider: do you go for an oil-lubricated air compressor or an oil-free one?

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Each option has advantages and disadvantages so, as industry experts, we are dedicating this blog to help you make that decision. We will take a detailed look at each one allowing you to decide which is best suited to your business &#; saving you time and money in the long run.

Understanding Oil Air Compressors

Let us start with oil-lubricated air compressors. As the name suggests, these air compressors use oil to lubricate moving parts in the compression chamber. This helps to reduce wear while simultaneously cooling the system &#; so you end up with an air compressor that runs smoothly, without the risk of overheating.

Advantages of oil-lubricated air compressors 

• The main benefit of oil-lubricated compressors is that they are likely to have a long lifespan as the oil keeps the internal moving parts in good order. For your business, this means that you will save money on replacing your compressors in the future.
  
• If anything does go wrong with an oil-lubricated compressor, it will probably require less work to fix the problem &#; the issues tend to be simpler and easier to rectify.
  
• Oil-lubricated air compressors are ideal for heavy-duty work, especially in industrial settings.
  
• Finally, the oil used in this compressor type means that they produce less heat and are much quieter when they are in operation.

Disadvantages of oil-lubricated air compressors

Oil-lubricated air compressors will require routine maintenance, more so than is required with oil-free air compressors. You will need to check the levels of oil, and oil changes will be required. Each model will be different, so be sure to consult the manufacturer&#;s guide to establish how regular the oil changes need to be.

Best suited for

Oil-lubricated air compressors are generally used in industries that require heavy-duty use and where air purity is less critical. The automotive, construction, and manufacturing industries are perfect for oiled air compressors &#; they can run for long periods and have a greater air capacity so can be used to power larger tools. They are not advised for medical or food processing industries or any other industry where any air contamination could be harmful as the compressed air may have traces of oil.

Oil Versus Oil-Free Air Compressors Guide

Exploring Oil-Free Air Compressors

Now let us look at oil-free air compressors. Every type of air compressor will require some kind of lubrication, but oil-free compressors will either have pre-lubricated cylinders or utilise self-lubricating materials, which negate the necessity for oil. It is important to note that these compressors will contain some oil, they are not technically oil-free, but the crucial factor is that this oil will not come into contact with the compressor.

Advantages of Oil-Free Air Compressors

• One of the biggest advantages of having an oil-free air compressor is that it will require less maintenance as there is no need for regular oil changes.
  
• Oil-free air compressors also deliver air without any oil contamination risks &#; in many industries, this is of huge importance as any contamination could destroy the product.
  
• As a general rule, oil-free air compressors will be smaller, lighter, and therefore more portable than their oil-based counterparts. This is ideal if they are to be used at multiple sites.

Disadvantages of Oil-Free Air Compressors

• Oil-free compressors are likely to be more expensive up front, largely because the internal workings are more complex to avoid using oil.
  
• They also have a potentially shorter lifespan due to the lack of lubrication in heavy-use scenarios.
  
• An oil-free compressor tends to make a lot more noise than oil-lubricated compressors. You may need to consider whether this is going to be disruptive to other parts of the business.

Best suited for

Oil-free air compressors are best suited for use in industries where air purity is paramount. The medical, pharmaceutical, food processing, and electronics industries, which are sensitive to air contamination, are perfect for an oil-free air compressor (but they may not be the best choice for heavy-duty industrial use).

Oil Versus Oil-Free Air Compressors Guide

Comparing Oil and Oil-Free Air Compressors

There are a few factors that represent the key differences between oil and oil-free air compressors, so let us break them down and consider them one at a time.

• Maintenance: Oil compressors will require more frequent maintenance, such as oil changes, while oil-free models require less maintenance.
  
• Cost: Oil-free compressors can be more expensive to buy, but you may end up saving some money on maintenance in the long run.
  
• Application suitability: Oil compressors are better for heavy-duty industrial applications, whereas oil-free compressors are better suited where air quality is crucial.
  
• Environmental impact: Oil-free compressors are more environmentally friendly due to less risk of oil spillage and contamination. They also tend to use less energy when in operation, as oil compressors need to move the oil through the compression chamber when in use.

Factors to Consider When Choosing an Air Compressor

There are a few key questions that you need to ask when choosing an air compressor.

• Application: How important is air purity for your operations? Will your new compressor be used for heavy-duty use?
  
• Maintenance capabilities: Does your business have the resources for the regular maintenance that oil compressors require?
  
• Budget: Can you afford the higher initial cost of an oil-free compressor? Is it justifiable for your operation?
  
• Environmental policies: Does an oil-free compressor align better with your company&#;s environmental commitments? Oil-lubricated compressors will also use more energy, which will have environmental consequences.

Maintenance Tips for Longevity

Whichever air compressor type you go for, you can do various things to increase your compressor&#;s longevity and avoid unnecessary maintenance costs. By following the guidelines below, you can keep your air compressor in the best possible condition and lengthen its life span.

• Always follow the manufacturer&#;s recommended maintenance schedule. There will be clear instructions about how often you need to perform various checks &#; make sure you put plans in place to ensure these checks happen. We offer Air Compressor Servicing which can save you a lot of hassle.
  
• If you have an oil-lubricated air compressor, make sure that you are regularly checking and changing the oil and filters. The frequency that you will need to change and check will depend on many different factors including the type of compressor you have and how often you use it. Make sure that you find out the best practices for your specific air compressor.
  
• If you have an oil-free compressor, remember to monitor for wear and tear on pre-lubricated parts. You may need to clean the air intake filters and conduct regular inspections of the hoses, power cables, seals, and fittings.
  
• Most air compressors will need to be stored in a clean, dry, location with a stable temperature. Find out what conditions your air compressor requires &#; this will help it to last longer without any impact on performance.
  

Applications and Industry Usage

The choice between oil-lubricated and oil-free compressors depends on the specific requirements of the industry and the intended application.

Oil-Lubricated Compressors

These compressors shine in industries where high power, durability, and reliability are paramount. Their ability to handle heavy-duty applications and operate in harsh environments makes them a preferred choice for:

• General Manufacturing: Oil-lubricated compressors are commonly used in manufacturing facilities for powering pneumatic tools, operating machinery, and providing compressed air for various processes. Their robust construction and ability to withstand continuous operation make them suitable for demanding production environments.
  
• Automotive Industry: Automotive repair shops and manufacturing plants rely on oil-lubricated compressors for tasks like tire inflation, paint spraying, and powering pneumatic tools. The high power and reliability of these compressors are essential for meeting the demands of the automotive sector.
  
• Construction Industry: Oil-lubricated compressors are frequently used on construction sites for powering pneumatic tools, operating jackhammers, and running other heavy-duty equipment. Their ability to withstand dusty and demanding conditions makes them a valuable asset in the construction industry.

Oil-Free Compressors

Oil-free compressors are indispensable in industries where air purity is of utmost importance. Their ability to deliver completely oil-free air makes them ideal for:

• Electronics Manufacturing: In the electronics industry, even the slightest trace of oil can damage delicate components and compromise product quality. Oil-free compressors ensure clean air, preventing contamination and ensuring the reliability of electronic devices.
  
• Pharmaceutical Industry: Compressed air is used in pharmaceutical manufacturing for various processes, including packaging, cleaning, and material handling. Oil-free compressors are essential to prevent contamination that could compromise drug safety and efficacy.
  
• Food and Beverage Industry: Oil-free air is critical for maintaining food safety and preventing spoilage. These compressors are used for tasks like packaging, aeration, and conveying food products, ensuring that the compressed air does not introduce any contaminants.
  
• Medical and Dental Facilities: In medical settings, oil-free air is used for various purposes, including powering surgical tools, ventilators, and dental equipment. The absence of oil contamination is crucial for patient safety and hygiene.

Understanding the specific requirements of your industry and application is key to selecting the right type of air compressor. By carefully considering the need for oil-free air or the demand for high power and reliability, you can make an informed decision that optimises performance and minimises risks.

Cost Implications

When choosing between oil-lubricated and oil-free air compressors, it&#;s important to consider not just the initial purchase price, but the total cost of ownership over the compressor&#;s lifespan. This includes upfront costs, ongoing maintenance expenses, and potential downtime costs.

Upfront Costs:

• Oil-Lubricated Compressors: Generally have a lower purchase price compared to oil-free compressors due to their simpler design and fewer specialised components.
  
• Oil-Free Compressors: Often have a higher upfront cost due to the more sophisticated technology required to achieve oil-free operation. This includes specialised air-end designs, filtration systems, and additional components to compensate for the lack of oil lubrication.

Ongoing Maintenance:

• Oil-Lubricated Compressors: Require regular oil changes, filter replacements, and maintenance of the oil separation system. These ongoing costs can add up over time, especially in high-usage scenarios.
  
• Oil-Free Compressors: Typically have lower maintenance requirements as they eliminate the need for oil changes and related maintenance tasks. However, they might require more frequent filter replacements and specialised maintenance for specific components.

Energy Efficiency:

• Oil-Lubricated Compressors: While generally reliable and powerful, oil-lubricated compressors are less energy-efficient than oil-free counterparts. The friction caused by oil lubrication and the need to cool the oil contributes to higher energy consumption.
  
• Oil-Free Compressors: Better energy utilisation due to the absence of oil-related friction and cooling needs. This translates to lower operating costs in the long run, especially in applications with high duty cycles.

Downtime Costs:

• Oil-Lubricated Compressors: Potential for downtime due to oil-related maintenance tasks like oil changes and filter replacements. Additionally, leaks or failures in the oil system can lead to unexpected downtime and costly repairs.
  
• Oil-Free Compressors: Generally, experiences less downtime related to maintenance compared to oil-lubricated compressors. However, they are not immune to breakdowns, and specialised maintenance might be required for certain components.

Overall, while oil-lubricated compressors might have a lower upfront cost, oil-free compressors often offer better energy efficiency and potentially lower maintenance costs in the long run. The specific cost implications can vary depending on the size, type, and usage of the compressor. It&#;s essential to carefully assess your specific needs and budget to make an informed decision.

Environmental Impact

Oil-free compressors are better for the environment, primarily due to the absence of oil in their operation. This eliminates the risk of oil spills, which can contaminate soil and water sources, harming ecosystems and wildlife. Additionally, oil-free compressors reduce the need for disposing used oil, a process that can pose environmental challenges.

On the other hand, oil-lubricated compressors have certain environmental challenges. The use of oil necessitates regular oil changes and disposal, which can contribute to pollution if not handled responsibly. Additionally, these compressors might have slightly higher emissions due to the energy required to compress air and cool the oil. Granted, modern oil-lubricated compressors are designed to minimise emissions.

In summary, oil-free compressors are more energy efficient compared to their oil-lubricated counterparts. This translates to reduced energy consumption, leading to a smaller carbon footprint and a more sustainable operation. By choosing oil-free compressors, businesses can contribute to environmental conservation efforts and reduce their impact on the planet.

Conclusion

When it comes to oil vs oil-free air compressors, only you will know what is best for your business. Both types of air compressors have valuable industrial applications &#; there is not one type that is better than the other, but there will be one that is more suited to your needs. Our job is to help you make the best decision.

Many businesses will make a quick decision and opt for the cheapest option if this saves them some money in the short term. They will probably end up with an air compressor with a shorter life span, and spend more on repairing and maintaining it. Do not make this mistake.

Published: 25/11/

Oil free air compressors: Pros and Cons

There are many different types of air compressors available and choosing the right one will depend on your needs and the application of the air compressor. 

For some applications of air compressors, purity of air is essential. As a result, oil free air compressors have been developed to meet quality standards and ensure safe manufacturing processes and end customers. 

Oil free air compressors provide a great solution for compressed air applications where air purity is important. In this guide, we&#;ll take a look at what oil free models are and their pros and cons to help you decide which air compressor is right for your application. 

What is an oil free air compressor?

Air compressors usually need to be lubricated with oil to ensure they keep running properly and to prevent friction between the moving parts. Lubricating oil is used for the pistons that draw in and compress the air inside. 

However, oil free air models can draw in, compress and store air with no added lubrication. The components inside the air compressor are coated with Teflon which provides a permanent lubrication and means that oil or additional lubrication is not required. 

The lack of lubrication is the biggest advantage of an oil free air compressor in comparison to a lubricated air compressor. 

Pros of oil free air compressors 

Less maintenance 

A normal air compressor needs regular oil changes, the regularity of which depends on the use and design of the air compressor. 

Once the oil has been changed, it also needs to be disposed of too which can take time and money. With an oil free air compressor, you do not need to worry about any of this and the lack of oil can make it a cheaper option over the long term. 

Lighter 

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Oil free air compressors have fewer parts inside so they weigh less than regular air compressors, making them a great choice for small to medium sized applications. 

Lower costs 

Thanks to their simple design, oil free air compressors usually cost less than oil lubricated compressors and they are built to last. With fewer parts inside, they do not require repair or replacement as often. 

Oil free air compressors can reduce operating costs by:

• Removing the cost of collecting and disposing of oil 

• Remove the cost of replacing air and oil separator elements 

• Remove the cost of ruined products, lost production or damaged reputation 

• Lower energy costs 

Oil free air compressors can also reduce maintenance costs by:

• Removing the need of expensive air filters to clean compressor air 

• Minimising downstream labour and outage related costs 

Environmentally friendly

Getting rid of oil from the air compressor is better for the environment because contaminants are not released into the air. 

By minimising oil usage, it also minimises the amount of oil that must be changed and disposed of. In addition, when running an oil lubricated model, large amounts of oil contaminated condensate which must also be properly disposed of in order to protect the environment. 

Reduced risk of contamination 

When compressed air encounters an end product, there is always a risk of contamination. The best way to avoid this is by not introducing oil into the airstream in the first place. 

Class 0 air allows businesses to avoid contamination risks which can increase the risks of product recalls and unnecessary downtime for a business. Contamination can harm brand reputation, the bottom line of a business and the health of customers so it&#;s important to avoid this in certain applications. 

Preventing contamination can protect assets too. Oil lubricated compressors always have traces of oil in the air they produce. These oil traces can build up on pneumatic equipment and other assets that require compressed air which can increase maintenance and replacement costs. 

Cons of oil free air compressors 

Whilst oil free air compressors have a number of benefits, there are also a number of cons to consider too to make sure you choose the right air compressor for your needs. 

Lower lifespan 

oil free air compressors are cheaper than their alternatives but they can have a lower lifespan than oil air compressors because the Teflon coating can wear off and the parts will become vulnerable to friction induced damage. 

Oil lubricated air compressors tend to last longer because the oil can be changed on a regular basis as and when it is required. 

Noise 

Oil free air compressors can be noisier than regular compressors due to the parts inside that rub together. However, modern oil free air compressors are now relatively quiet which is achieved through sound dampening and soundproofing techniques. 

Which industries are oil free air compressors best suited to? 

Compressed air from an air compressor comes into contact with almost everything, including finished products. Ensuring that air supply does not become contaminated is essential in the following industries: 

Medical and pharmaceutical

In this industry, cleanliness is a critical factor in the quality and performance of the end products. The product being produced will dictate the risk tolerance for contaminants such as oil or moisture. Due to the critical nature of the products, every manufacturing touchpoint such as tablet coating and product drying needs to be reviewed and this will include the risk that comes from compressed air too. 

Food and beverage 

It&#;s essential to avoid product contamination which can lead to product recalls and damaged brand reputation. An oil free air compressor can prevent the air supply from being contaminated and remove the risk.

Electronics 

For applications such as PC board cleaning, delivering clean and dry compressed air is critical for minimising contamination in the end product. The highest class of air purity allows manufacturers to protect sensitive manufacturing equipment and the finished products. 

Textiles 

A high quality stream of compressed air is important for preventing fabric staining and loss of production. Having the highest class of air purity is essential for delivering high quality, oil free manufactured products. 

If you&#;d like more information on the pros and cons of oil free air compressors or which compressor to choose for your application, please contact our expert team. 

 

 

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