Why you should still monitor an oil-free compressor for Residual oil content

Who needs oil-free compressed air and why?
Oil contamination in compressed air can cause production downtime and loss of quality, as the pipework network, production facilities and end products can become contaminated. Oil-free compressed air is therefore particularly important in the food and beverage industry, the pharmaceutical industry and in medical applications. Other applications include chemical and petrochemical process engineering, electronics and semiconductor manufacturing, automotive painting, the paper industry and textile manufacturing. In industries such as brewing, where nitrogen is used to prevent oxidation and to maintain pressure, the purity of the compressed air is crucial. Oil-free compressed air, combined with nitrogen generators, can ensure product quality and reduce costs by producing nitrogen in-house.

Oil-free versus oil lubricated
When selecting a compressor, it is important to distinguish between "oil-lubricated" and "oil-free" solutions. Both types of compressor supply compressed air, but differ in their lubrication. Oil-lubricated compressors use oil to lubricate the internal components, while oil-free compressors use self-lubricating or pre-lubricated materials to keep the parts moving efficiently.

When is "oil-free" the right choice?
Oil-free compressors are particularly suitable for industries where even the smallest amount of oil can damage equipment or spoil products. This applies to the pharmaceutical, food and beverage, electronics, laboratory and similar industries. However, if oil is not a critical factor in your applications, an oil-lubricated or "technically oil-free" system could be an option. Oil-free compressors are more expensive to purchase and more energy inefficient than oil-lubricated compressors. It is therefore crucial to ensure that the compressed air from your compressors meets your quality requirements in order to avoid unnecessary costs and energy losses.

Limitations of oil-free compressors
Oil-free compressors do not necessarily deliver ISO quality class 1 compressed air, as they draw in ambient air that may contain hydrocarbons. Activated carbon filters and activated carbon absorbers are often installed to remove these hydrocarbons. These filters become saturated over time and can release hydrocarbons again.

Types of intake for air compressors

• Free intake - With free intake, air is drawn in directly from the environment. This method is simple and cost-effective, but is only suitable for clean environments without impurities.
• Filtered intake - Filtered intake uses pre-filters and fine filters to remove particles and impurities from the air. This is particularly important in dusty environments to extend the life of the compressor and ensure high air quality.
• External intake - External intake draws air from a remote, cleaner environment. This method is ideal in dirty or extremely hot operating environments to ensure clean, tempered air at all times and increase the efficiency and longevity of the compressor.

Compressed air treatment to comply with ISO 8573-1 classes
Several steps are necessary to improve compressed air quality after compression and achieve higher ISO 8573-1 classes:

• Filtration: use of pre-filters, fine filters and micro-filters to remove particles.
• Drying: Use of refrigeration dryers, desiccant dryers and membrane dryers to reduce moisture.
• Oil removal: Use of oil separators, activated carbon filters or, if necessary, a catalytic oxidation system to remove oil and oil vapours.
• Combined filter units: Integration of different filter technologies in one system.
• Regular maintenance and monitoring: regular maintenance of filters and dryers.

These measures ensure high compressed air quality and fulfil the requirements of the ISO 8573-1 standard.

Continuous monitoring and measuring
With the OIL CHECK 500, you can continuously measure and document the purity of your compressed air and prevent expensive production downtime. These measurements help you to assess the effectiveness of your compressed air treatment and to change the activated carbon filter/bulk filter as required.

Would you like to continuously monitor the quality of your Compressed air?

Use the OIL CHECK 500 to continuously monitor your Compressed air quality and ensure that your production always meets the highest standards. You can find more information on the product page or call us for a personal consultation and customised solutions for your compressed air monitoring. Take the initiative now and optimise your production processes!