At Pneuparts, we see the most beautiful compressed air installations every day.. Every day, our driven specialists work passionately on systems that keep companies running. However, in practice we often come across an invisible culprit that causes unnecessary costs: moisture.  

 

Moisture in your pipes may seem harmless, but it is the biggest enemy of your pneumatic components. 

 

In this article, we explain how moisture is created, what damage it causes and more importantly how to keep your system bone dry.

 

 

Why moisture in compressed air poses a direct risk to your business When you use a compressor, you suck in ambient air. This air always contains water vapour. During compression, the air heats up, so that this vapor remains invisible. As soon as the compressed air leaves the compressor and cools down in your pipe network, this vapor turns into liquid condensate. This process is inevitable, but the consequences of this water in your system are often very detrimental to your process.   The first major problem we see with customers is internal corrosion. Water flowing through your pipes affects the material and causes rust particles. These particles come off and end up in your precious valves and cylinders. This causes blockages and leaks that make your system unnecessarily slow.   In addition, water washes away the necessary lubricating grease from your pneumatic components. Without this lubrication, additional friction is created, which directly leads to faster wear and higher energy costs.   In addition, moisture has a negative impact on the quality of your end product. Think, for example, of spraying where water droplets cause craters in the paint, or of the food industry where hygiene is crucial.

Understanding the technical cause of condensation

To combat moisture, it is important that you understand how it develops. 

 

Air has a limited capacity to hold water vapor, depending on the temperature and pressure. We call this point of saturation the dew point. The higher the pressure, the less water the air can hold. Because a compressor compresses the air very compactly, there is simply too much moisture in it for the small volume that remains.

 

Actually, you can best compare the compressed air to a sponge that sucks full of water. When your compressor absorbs air from the environment, it also sucks up water vapor without noticing. But as soon as the machine compresses that air, the same thing happens as when you squeeze a wet sponge hard: the water comes out on all sides. In your compressed air system, this means that large buckets of water can flow through your pipes every day if you don't take measures.

 

At Pneuparts, we therefore always recommend not only looking at the compressor, but at the entire chain from air output to the machine.

 

A step-by-step plan for a bone-dry compressed air system

Keeping your system dry is not rocket science, provided you follow the right steps. We have drawn up a practical plan that you can apply immediately to improve air quality.

Step 1: Check the aftercooler

Most modern compressors have a built-in aftercooler. This already significantly lowers the temperature of the outgoing air. Regularly check that the fins of this cooler are clean. Dust and dirt reduce the cooling capacity, so that more heat (and therefore moisture) enters the pipe network.

Step 2: Install Automatic Condensate Drains

Water often collects at the lowest points of your system and in the compressed air tank. Manual taps are often forgotten, which causes the tank to fill up with water and reduce storage capacity. We recommend electronic, level-controlled draining . These only discharge water and no precious compressed air, which is also good for your energy bill. You can often find it in compressors from about 11kw, the lower installation capacities often do not have this.

Step 3: Choosing the Right Dryer

For most industrial applications, a refrigerant dryer is the standard. This cools the air to about 3 degrees Celsius and removes the condensed water. Do you have processes that take place outdoors or do you work in the pharmaceutical sector? Then an adsorption dryer is often necessary to achieve an extremely low dew point. Where pressure dew points of up to +/-70 degrees are possible.

Step 4: Filtration at the points of use

Even with a central dryer, there may still be residual moisture or dirt in the pipes. Therefore, always place a Filter Regulator right in front of your machine. This is the final step that protects your equipment from impurities.

 

Thebenefits of a dry installation for your company

When you take moisture control seriously, you notice it immediately in daily practice. The reliability of your machines increases. 

 

Valves no longer stick, cylinders continue to run smoothly. Which means: less unexpected downtime, lower maintenance costs in the long run and you also save on energy.

 

A system that is clean and dry suffers less from internal resistance and leaks caused by corrosion. 

 

Our customers often find that they have earned back their investment in a dryer or filtration system within a year. This is simply because far fewer repairs are needed and the loss of valuable compressed air stops.

Time for a check-up of your compressed air system

At Pneuparts, we are there for you every day with practical advice and the right items that fit your situation perfectly. Together, we ensure a system that not only works well today, but also delivers maximum returns in the future.

 

Do you suspect that there is moisture in your pipes, or do you want to have your current installation optimized by a specialist? Please contact us or view our extensive range of dryers, condensate drain and filters. We are happy to help you.

 

Frequently Asked Questions (FAQ)

Is a water separator alone not enough? 

A water separator only removes the liquid water, but not the water vapor. As soon as the air cools down further, condensation forms again. For a truly safe system, you almost always need a dryer.

 

What is the difference between a refrigerant dryer and an adsorption dryer? 

A refrigerant dryer works like a refrigerator and is suitable for most indoor applications. An adsorption dryer uses special granules to absorb moisture and blow it off back into the ambient air during the rinsing process, as a guideline it is assumed that an adsorption dryer needs about 15 to 20% purge air, which when applied incorrectly costs an unnecessary amount of energy.

 

How often should I check my filters? 

We recommend inspecting your filters and replacing the elements at least once every six months. In dusty environments or with intensive use, this may be necessary more often to keep the flow optimal.

 

 

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