When to upgrade from a reciprocating to a rotary screw air compressor

Those responsible for managing a facility’s infrastructure, whether it be manufacturing, food processing, automotive, or even a shopping centre or hospital, face capital expenditure decisions on a regular basis. They also know that compressed air is a piece of the infrastructure puzzle they must get right.

Many customers start out with a reciprocating air compressor system. They are cheaper, reliable, and do the job while the business is scaling. However, upgrading is inevitable as the company grows or the facility becomes larger. At Pilot Air, we are seeing a sizeable shift toward rotary screw air compressors when the time comes to reevaluate the compressed air system.

In recent articles, we’ve discussed the superior energy efficiencies of rotary screw air compressors. These systems typically deliver more air per KW than their reciprocating counterparts. The rotary screw construction minimises energy loss, and the high CFM output in horsepower enables greater workloads at the same power.

The ALTA TEC rotary screw compressor range offered by Pilot Air is fitted with variable speed drives. These systems adjust output to mirror demand, enabling measurable energy savings. The variable drive saves energy, reduces operational costs, and helps businesses meet their sustainability goals through reduced carbon emissions.

Our account management and sales team often receive questions about when to upgrade. At Pilot Air, we are not in the business of upgrading a customer for upgrade’s sake. We take a long-term strategic approach to their business. Some initial indications suggest it is time to talk to one of our professionals.

• Demand has increased, whether your production has grown or you’ve added additional air-driven equipment and tooling. This is a common reason to reevaluate your existing compressor setup. Often, reciprocating air compressor systems are required to work longer cycles and are, therefore, no longer capable of meeting the increased demand.
• More frequent maintenance and repairs. When demand increases, the wear and tear on reciprocating air compressors will result in more frequent maintenance and costly repairs. Piston rings and valves are the more common issues, and the increasing need for oil changes adds to the cost, plus downtime. When you notice this is happening, it is time to consider a more heavy-duty solution, such as a rotary screw compressed air solution.
• Duty cycles are a significant factor. Reciprocating air compressors are not designed to run continuously. They run into major issues with overheating and excess wear, not to mention the power they drain to keep going for long periods. When you find your production needs to be tailored around compressor cooldowns or you are using multiple smaller units on a rotation schedule, it is a clear sign that upgrading to a rotary screw air compressor is the next move.
• Reciprocating air compressors are noisy and prone to vibration. The harder they need to work, the louder they can get, and the more vibration they experience. This can become an OHS issue or just a plain pain in the ears. If the excessive noise is causing issues, a quieter, more efficient rotary compressor is the answer.

When your current system displays any or all of the above issues, it is time to talk to our team about a rotary screw compressed air solution. In the long run, it will save considerable money across several key areas.

• Energy costs will be much lower, up to 20% annually, and for larger installations, a Pilot Air ALTA-TEC rotary screw air compressor can pay for itself in 24 months.
• Increased productivity due to the continuous availability of compressed air when you need it for as long as you need it.
• Significantly reduced maintenance and repair, meaning the unit works harder for longer with reduced downtime.

At Pilot Air, we manufacture high-quality reciprocating air compressors, and they have their place when you need portability, short and infrequent compressed air, and a unit to run on standard power. For small workshops, they can be the ideal solution. However, for larger enterprises, a rotary screw compressed air solution delivers on four key pillars:

• A rotary screw air compressor is designed and built to operate continuously. It can run 100% of the time required without overheating.
• They offer superior performance, energy efficiency, and lower lifecycle costs than reciprocating air compressors.
• A rotary screw air compressor system requires less maintenance even under the high strain of an industrial setting.
• They are much quieter than a reciprocating air compressor. This dramatically improves work environments and means the unit(s) can be positioned closer to the point of use if necessary.

While a rotary screw compressor’s up-front cost is greater than that of a reciprocating system, the energy savings, efficiency, and productivity gains, and reduced maintenance costs quickly deliver a return on investment.

Upgrading from a reciprocating air compressor to a rotary screw air compressor is not a matter of swapping one out for the other. There is no one-size-fits-all solution, which is why we take the time to conduct a comprehensive analysis of your site to recommend the best possible rotary screw air compressor configuration that not only meets your needs now but is also scalable and can help future-proof your business.

We have over 50 years of local experience supplying high-end rotary screw air compressor solutions across a broad range of industries. If one of our standard models isn’t suitable, we customise a solution that is. This can include air receiver tanks, filtration units, dryers, and air distribution systems that optimise your business’s performance. We provide continued support from design through to installation and maintenance.

The team and I believe in long-term business relationships. As an Australian-owned and family-owned business, our values of quality and service ripple through every touchpoint. Our value is competitive, our customer service is unmatched, and our attention to detail is clear in every unit we deliver.

Pilot Air is one of Australia’s leading suppliers of rotary screw air compressors. Our team is qualified to conduct a diagnostic assessment and install the most suitable compressed air infrastructure with built-in scalability for your immediate needs. Pilot Air is proudly Australian-owned and independent, with onshore maintenance and service, skilled technicians, and a large inventory of spare parts. Contact our team today.