Summary of Key Sections
Compressed air is used in a wide range of industries—from food and beverage to pharmaceuticals, electronics, and automotive manufacturing. Contaminants such as water vapor, oil, and particulates can compromise product quality, damage equipment, and even pose safety risks. Poor air quality can lead to unplanned downtime, increased maintenance costs, and product recalls in regulated industries.
For example, in a food processing plant, oil or moisture in the air line can contaminate packaging or ingredients, leading to health risks and regulatory violations. This example highlights the importance of tailoring air preparation to the specific needs of each application.
Additional Considerations:
The international standard ISO 8573 provides a comprehensive framework for measuring and classifying compressed air contaminants. It breaks down air quality into three main categories:
Each category is assigned a class rating, with Class 1 being the highest quality. For example, ISO 8573-1:2010 is the most commonly referenced part of the standard, specifying the purity classes for compressed air. A typical classification might look like ISO 8573-1:2010 [1:2:1], meaning Class 1 for particles, Class 2 for water, and Class 1 for oil.
Additional Notes:
To meet the desired ISO 8573 class, various air treatment technologies are used in combination. These technologies are typically arranged in stages to progressively remove contaminants.
Water is one of the most common and damaging contaminants in compressed air. It can cause corrosion, damage pneumatic tools, and affect product quality. Key technologies include:
Solid particles can originate from ambient air, the compressor, or the piping system. To remove them:
Oil contamination can come from lubricated compressors or ambient sources. Removal methods include:
Collected water and oil must be safely discharged:
Different industries have unique requirements for compressed air quality:
Emerging Industry Needs:
Festo partnered with TNO to enhance compressed air quality at the Van Leeuwenhoek Laboratory, a leading research facility in nanotechnology. Faced with the challenge of needing both increased capacity and superior air quality, Festo conducted a comprehensive pre-audit and collaborated with Royal HaskoningDHV to design a two-tier compressed air system.
This system adheres to ISO 8573 standards, delivering extremely dry compressed air (class 2.1.1) for sensitive tests while providing standard quality air (class 2.4.1) for other applications. This tailored solution improved reliability and efficiency, optimized energy consumption, and demonstrated the critical role of ISO standards in achieving high-quality compressed air for industrial needs.
Even with the best intentions, many factories and maintenance engineers make avoidable mistakes when designing or maintaining their air preparation systems:
Avoiding these pitfalls starts with a proper system assessment and regular monitoring of air quality.
1. Assess Application Requirements
2. Evaluate Current Compressed Air System
3. Design and Implement Air Treatment Solutions
4. Maintenance and Monitoring
5. Documentation and Continuous Improvement
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