An air dryer is a key part of an air compressor system. It gets rid of moisture from compressed air. Air dryers do more than just protect equipment—they also keep industrial processes running smoothly. Unfortunately, improper use can lead to problems like device damage and increasingly wasteful energy use. In this article, we'll discuss 5 common mistakes people make when operating an air dryer and offer tips to overcome them.
1. Ignoring Routine Maintenance
One common mistake is forgetting or even postponing air dryer maintenance. People often ignore components like filters, desiccant media (on desiccant air dryers), and pressure sensors. When the filter gets clogged or the desiccant media is saturated, the air dryer doesn't work as well, so the air produced is humid. This can cause corrosion of the duct or damage to the production machine.
For example, a food factory was forced to stop production for a few days because their air dryer suddenly died. Of course, they don't want to take the risk of continuing to produce food without an air dryer because the food they produce could be contaminated by dust or other harmful small particles. Upon inspection, the air filter on the air dryer was found to be full of dust, which should be cleaned regularly. To prevent this from happening to you or your business, schedule monthly maintenance to check the air dryer's main components. If you're unsure or don't know how to do this, ask a professional technician for help. This will not only save you time, but also prevent higher repair costs.
2. Improper Selection of Air Dryer
Picking an air dryer that doesn't meet your needs is a big mistake. Refrigerated air dryers are great for general use, but not so much for environments that require very low humidity, like the pharmaceutical or electronics industries. A desiccant air dryer is better for these environments because it can reduce humidity to a very low dew point.
We found that using a refrigerated air dryer in a vehicle repair shop wasn't the best idea. The air it produced was often still damp, which affected the pneumatic tools they used. This humid air can also shorten the life of the tool and increase maintenance costs. So, before you buy an air dryer, it's a good idea to check with the vendor or manufacturer of the appliance on the operating pressure, air temperature, and humidity level required.
3. Incorrect Pressure Setting
It's important to make sure that the incoming and outgoing air pressure in the air dryer is in line with the equipment specifications. If the pressure is too high, it can damage the internal components pretty quickly, and if it's too low, it won't be very effective at drying the air.
For instance, an automotive company we worked with had issues with their pneumatic tools not performing as well as they should have been. When we looked into it, we found that the pressure going into the air dryer was below the recommended standard. The solution was to use an air pressure regulator, like a pressure regulator, to make sure the pressure stays stable. It's also a good idea to check the pressure regularly with a manometer to make sure you avoid similar problems in the future.
4. Using an Air Dryer with Unsuitable Capacity
It's often the case that air dryers that are too small or too large for your needs are chosen based on price. However, this can lead to inefficiencies down the line. If your air dryer has a small capacity, it won't be able to handle large airflow, so it won't be able to remove moisture properly. On the other hand, if your air dryer has too large a capacity, it'll just end up wasting energy and money.
For instance, a soft drink factory uses a small air dryer with a large compressor system. This often leads to overworking the device, which then breaks down in less than two years. The solution is to make sure the airflow capacity (in liters per second or cubic feet per minute) matches the needs and consider the potential future growth of the business.
5. Not Fixing Air Leaks Immediately
Air leaks in the compressor system are a real pain for the air dryer because they make the job harder and waste a lot of energy. We heard about a textile factory that got hit with a huge spike in electricity bills because of a small leak in the air pipe that wasn't fixed right away.
To find out where there's a leak, use a mix of liquid soap and water and put it on the pipes and joints. If you see bubbles, get the pipe fixed with sealant or replace the part that's damaged. Making sure there aren't any leaks will help the air dryer work better and can save you money on running costs.
Avoid these mistakes to keep your air dryer in top form, extend its life, and cut potential losses. Get to know how your air dryer works and what it needs, and you'll make a small investment that can have a big impact on your business or operations.
