The number one reason to rebuild your air compressor air-end is economic. Rebuilding the air end will extend the life of your air compressor. There are three basic considerations when deciding to buy a new compressor air-end or rebuilding the air end before it fails.
Consideration 1: How do I prevent a failure of my compressor air end?
The best way to prevent a failure of your compressor is a proper maintenance and testing program. Following the manufacturer’s recommended maintenance schedules and changing the oil regularly will help keep the compressor “clean” and avoid the most common breakdown caused when contaminated oil damages the bearings and seals in the compressor air-end.
Consideration 2: When should you rebuild your compressor airend?
The best time to rebuild your compressor air end is before it fails. The life of the air-end depends on manufacturer, the environment the compressor runs in, the maintenance program that has been used on the compressor, the type of oil the compressor uses, and the way that the compressor is used. The most critical factor is the maintenance program because proper maintenance of a compressor will overcome most of the other factors. You should be running routine analysis of oil, bearing vibration, bearing temperature, and air end temperature. If these parameters start to show unwanted variances, it is probable time to rebuild the air end.
Consideration 3: How much will it cost to rebuild my air-end?
Air end rebuild costs vary depending on the manufacturer, the HP of the machine, and the condition, but in general a complete air end rebuild can be accomplished for half the price of a new air end. You must factor in costs for removal and installation, as well as any shipping costs to and from the rebuilder. Oil and filters should also be budgeted.
When looking for an air end rebuilder, go to one that you can trust such as OEM Air Compressor in Chicago. OEM Air Compressor guarantees their stationary remanufactured airends to be free from defects in material replaced or labor performed with a Lifetime Warranty. To obtain warranty coverage, the customer must complete the warranty registration for within 30 days upon initial start-up and purchase the replacement parts and lubricants from them every 2000 hrs.
To see a list of which manufacturers, models, and base prices, go to their airend rebuilding page.
Find air end pricing for these manufacturers:
Air-End Rebuilding for Atlas Copco® Air Compressors
Air-End Rebuilding for Bauer® Air Compressors
Air-End Rebuilding for Champion® Air Compressors
Air-End Rebuilding for CompAir® Air Compressors
Air-End Rebuilding foe Curtis Toledo® Air Compressors
Air-End Rebuilding for Gardner Denver® Air Compressors
Air-End Rebuilding for Ingersoll-Rand® Air Compressors
Air-End Rebuilding for Joy® Air Compressors
Air-End Rebuilding foe Kaeser® Air Compressors
Air-End Rebuilding for LeRoi® Air Compressors
Air-End Rebuilding for Quincy® Air Compressors
Air-End Rebuilding for Sullair® Air Compressors
Air-End Rebuilding for Tamrotor® Air Compressors
Air-End Rebuilding for Worthington® Air Compressors
The heart of an air compressor is the screw element which is also called air-end. The air-end is the most important part of any screw-type compressor. It’s that part of the machine where the actual compression takes place. It is the heart of the rotary screw air compressor.
They are constant flow (volume) with variable pressure compressors. Which mean that at a given speed (rpm), they always supply the same amount of air (in liters per second for example), but can do so at different pressures.
Why are they so popular? Since it’s a continuous process (as opposed to reciprocating piston compressors) they supply a steady, non-pulsating air flow, with minimum vibrations and maintenance and maximum lifetime.
How does an air-end work? Inside the compressor element are two screws that turn in opposite directions. The rotary screw compressor is a “positive displacement” compressor, which means that the air is physically squeezed together by an external force (like piston and scroll compressors).
In the case of the rotary screw, the air gets trapped between the two rotors. The rotors have a special design for optimal efficiency and performance. One rotor is the “male” and the other is the “female”. The air gets sucked in on one side (cold, low-pressure), and gets trapped between the rotors, and then is discharged out the other side (hot, high pressure). This compression requires power, which is usually supplied by a large electro motor.
There are two basic types of screw compressors: oil-injected and oil-free. Oil injected rotary screw compressors are the most common, since they are the cheaper of the two. Oil-free screw compressors are used in applications where the compressed air must be 100% oil free, like for food processing and chemical plants.
They can operate 24/7, 365 days a year. The normal lifespan of a screw element is about 40.000 running hours, before a complete overhaul is necessary. That's when the folks at www.oemair.com come in. You can send in your air-end to be rebuilt to original specs and they offer a guarantee that is the best in the business. To learn more about this service, visit http://oemaircompressor.com/aircompressorairendrebuilding.aspx.
Rebuilding an air-end can save you thousands of dollars. Air Compressors are expensive and it doesn't make sense to get a new one when the air-end is at the end of its service life. Industrial Air-end rebuilding just makes sense (and dollars).