From manufacturing, automotive, and food processing, to pharmaceuticals, compressed air systems are a big part of many industries. Compressed air filters, although sometimes neglected or hard to find, play a critical role in providing clean, moisture-free air to protect the equipment it is connected to, ensure optimal product quality, and reduce equipment downtime.
Like any other filter, compressed air filters will eventually get clogged, fill with moisture, or just plain stop performing. Once this occurs, they permit dirt, oil, dust, moisture, rust, or bacteria to get through. Contaminants can cause machinery to fail, create unsafe conditions in your operation, and incur costly repairs or expenses from unnecessary downtime. Therefore, it is important to recognize the signals or conditions that inform you when your compressed air filter needs to be changed in order to keep your operation running smoothly and efficiently.
A steady and consistent drop in the air pressure at the required point of use is a sign of failing compressed air filters. As the filter becomes saturated with dust, oil aerosols, or other particulates, it builds up resistance to the air and makes it tough to pass through. The result is a noticeable drop in pressure that will have a direct impact on the performance of your machinery.
Many industries that rely on timing and precision, which means too little operational air pressure, can adversely reduce productivity, increase job times, and cause machines to stop or shut down due to insufficient operating pressure. When pressure drops because of a malfunctioning compressed air filter, it could create unnecessary service calls, costs involving parts and labor, or even upgrades when the problem might just have been resolved with a filter replacement, for example.
Observing particulates or oil residue in the airline is an indication that a filter is no longer doing its job. A compressed air system is designed to deliver quality compressed air that is clean and dry to downstream tools and processes. When you start seeing fine particulates, rust flakes, oil mist, or any other material escaping through the lines, it confirms that contaminants are bypassing the filter media, or the compressed air filter is so saturated that it can no longer hold any more debris.
The contamination creates a rapid path to corrosion of pneumatic components, reduction in quality of the final product, and accelerated wear on costly equipment. In industries like electronics, food processing, painting, etc., the tiniest foreign particles can lead to defective products, causing unnecessary rework and disappointed customers. This is one of the most obvious signs that the compressed air filters need replacement.
When compressed air filters become clogged or are not working efficiently, your compressed air system operates harder to achieve the desired pressure and air volume. This means using more electricity, which can result in inexplicable increases in energy bills for your facility. In some cases, the inefficient use of electricity can become an unseen drain on your resources over time, especially in operations where compressors are running all the time.
Although the negative impact may not happen immediately, the increase in energy consumption due to dirty filters can quickly add up, especially if not enough attention is being paid. The solution is to perform regular audits and checks for filter efficiency. Taking the additional and often surprisingly small step of changing a clogged air filter can restore efficiency to the system and eliminate power draw, leading to substantial savings.
Does your compressed air system seem to require maintenance or experience unexplained downtime regularly? One of the causes can be as simple as an air filter failure. A dirty or even saturated one ruins the entire system by allowing contaminants to get to the air compressor components. Valves start to stick, actuators behave erratically, and precision tools in manufacturing may display increased wear. Ultimately, the service and the cost of parts associated with a neglected filter will add up quickly. Routine and timely scheduled replacement can prevent many of the issues mentioned above and provide more efficient operation, fewer service calls, and increased uptime.
Compressed air filters are small but can have a large influence on performance and equipment protection. By routinely monitoring and replacing them, you are preventing the costs of neglected air filtering.