A wide range of industrial and manufacturing operations rely on compressed air. However, this effective utility is not without limitations. There are some issues relating to contamination. As a result, air compressor filters are often fitted as part of a complete air filter system purification. It guarantees that impurities are kept to acceptable levels and that the compressed air system runs safely, efficiently, and economically.
Filter components must be replaced on a regular basis to provide a constant supply of optimal quality compressed air. So today, in this article, we’ll focus on why air filter maintenance of a compressed air system is required and the benefits of changing them on a regular basis.
Why is there a need to replace the compressed air filter elements from time to time?
Filtration is the core of every purification system. When it comes to a compressed air system, the main responsibility of filters is the removal of nine of the ten principal pollutants present in a compressed air system. Six of the ten pollutants are reduced by coalescing filters, which are among the essential pieces of filtration equipment. A coalescing filter, a dry particle filter element, or a blend of both are commonly used in compressed air filtering systems. Oil, as well as water droplets, are removed from the air by coalescing filters. On the other hand, dust particles and microorganisms are trapped by dry particulate filters. Both systems need a filter element that is generally in the form of a cartridge.
Compressed air filters make use of highly specialized filtering media within their filter elements to reduce pollution. These components work under extremely vigorous circumstances. As a result, filtration media deteriorates with time. When it is degraded, the air quality gets compromised as it no longer can be maintained.
An optimally efficient filter element must be able to endure the following extreme conditions seen in an industrial compressed air filtering system:
- Tremendous pressure fluctuations
- Extreme temperature variations
- Changing airspeeds
- Corrosive substances
- Excessive humidity variations
These circumstances lead the filter element to degrade over time, reducing its capacity to remove pollutants effectively. There filter media needs to be replaced from time to time to maintain optimal performance.
What happens to a filter element’s filtering medium if it is damaged?
Even the tiniest hole can cause havoc. The thing that needs to be understood here is that compressed air will always seek the route of least resistance. Therefore, if there is any damage in the filter media, compressed air will push its way through it, ripping and rupturing the element. All of the contaminants will be pushed downstream as a consequence of this.
What happens if you don’t replace the air filters?
The expense of replacing the elements and air filter maintenance is among the primary reasons consumers opt not to update filter elements. However, the cost of inadequate filtering is sometimes several times that of a filter element!
If you don’t change the filter, the compressed air filter system, along with the air accessories as well as downstream products, will be severely impacted. As a result, the performance of the system suffers, expenses rise, and the probability of failure increases.
Furthermore, failing to change the filter element might result in:
- Equipment corrosion.
- Contamination of the network, leading to deteriorated products and contamination at the point of use.
- Any damage caused to the production machinery will result in downtime.
- Rise in Long-term costs.
Air compressor filters should be updated according to the manufacturer’s instructions for optimal performance, cost-effectiveness, and energy economy. For major corporations, proper utilization leads to significant energy savings.
With the continuous usage, additional particles will cling to the filter media, lowering the surface area available for air to pass through. The pressure drop increases, raising the entire system’s operating expenses. Therefore, it’s critical to replace the filter after the suggested time period for maximum energy savings and efficiency.
Benefits of changing the Air Filter Elements
Each air filter element has a limited life span, and the manufacturer usually recommends changing the filter within a certain time span to provide the best possible air quality.
While replacing compressed air filter elements may appear to be a small matter, doing so on a regular basis has various advantages.
Safer working of equipment
By replacing your filters from time to time, you can safeguard your downstream equipment, workers, and operations from harmful impurities. This will protect your staff from dangerous situations such as poor air quality, overheated equipment, or system failures.
Lower operational costs
Regularly changing the air filter components lowers the chance of system failure. If not done in a timely manner, it can lead to adversely affected performance, expensive repairs, and downtime. Your compressor system will have to work harder to generate enough airflow if you don’t maintain your filters properly. This results in excessive compressor wear and high energy consumption, raising total operating costs and reducing compressor service life.
Increased profitability and improved productivity
You can boost the efficiency and profitability of your operations by changing your filters on a regular basis. Your system will run more efficiently with filtered, unrestricted airflow.
Protection of Adsorption Dryer Beds
Adsorption dryer beds in desiccant systems can work at maximum efficiency when a new filter is used. They can work more effectively with less oil and solid particles in the compressed air flowing over the beds.
Peace of mind
When you replace the filter elements, you can rest easy knowing that your system is working at peak performance and safety. Your system will run more efficiently, and your workers will work in a healthier, safer environment.
We hope you found this article to be useful.
It’s vital to change the filter elements of your air compressor system on a regular basis to keep it running smoothly. Additionally, if you are looking to get custom air filters built for your air filtration system, you can get in touch with US Home Filter. Our professionals can help you find the most suitable air filter that fits your requirements.
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