Compressed air is widely used in the industrial sector, manufacturing, healthcare, and numerous other fields. Indeed, approximately 10% of commercial energy is used to produce it.
Air compressors can compress air up to certain realistic limits. For many industrial compressors, 13 bar is a common pressure limitation without straining the system or compromising safety. When higher pressure levels are required, adding an air booster to the compressor system amplifies existing pressures to the desired levels.
Using both a compressor and an air booster is more efficient, cost-effective, and safer than relying solely on high-pressure compressors. For applications requiring 40 bar, such as PET bottle blowing, or even up to 300 bar in specialised industries, boosters extend the capabilities of existing systems without necessitating expensive upgrades to the primary compressor.
What is a Compressed Air Booster?
A compressed air booster increases the pressure of air that has already been compressed. Standard compressors typically produce around 13 bar, but some tasks need higher pressure.
We installed one at Roberts Manufacturing in Leeds last month. The unit sits between their main compressor and the testing equipment, taking up about a metre of floor space. It is bolted to a concrete pad to reduce vibration.
Most boosters use pistons to compress the air further. A basic 5:1 model can take 13 bar inlet pressure up to 65 bar. The workshop at Northern Plastics runs theirs for three hours each morning, then switches it off during lunch.
They are useful for jobs like PET bottle production, gas bottling or pressure testing. The Bentley’s brewery in Yorkshire uses one for their bottling line; it runs during the Wednesday and Thursday shifts when they package their ale.
Boosters do not run continuously. They switch on when higher pressure is needed, which saves electricity. The maintenance schedule is straightforward – oil changes twice yearly and seal replacement annually. Most models have a small hour counter on the side panel that helps track service intervals.
A booster is more practical than replacing the entire compressed air system if your factory needs higher pressure, but only for certain tasks.
Types of Compressed Air Boosters
There are different types of air boosters on the market, including single-stage, two-stage, and variable-speed versions.
In some circumstances, there are oil-free air pressure boosters and oil-injection versions; the latter is more common. Oil-free boosters are appropriate for food and beverage industries, healthcare, etc.
Below are the three types of compressed air boosters:
Single-Stage Boosters
Single-stage boosters compress air in a single process. They typically increase pressure from 2–10 bar to final pressures of 15–30 bar, with some models achieving up to 40 bar. These boosters are straightforward and efficient for applications requiring moderate pressure boosts.
Two-Stage Boosters
Two-stage boosters compress air in two steps, allowing for significantly higher pressures. They are ideal for industries requiring 40 bar or more, such as PET bottle manufacturing, where single-stage boosters might fall short.
Variable-Speed Boosters
Variable-speed boosters provide advanced configurability by adjusting pressurisation settings in real time based on demand. This improves energy efficiency, reduces over-pressurisation, and minimises wear and tear on the system. These boosters are especially suitable for dynamic operations with varying pressure requirements
Key Components of a Compressed Air Booster
The common key components of a compressed air booster are:
The inlet valve permits air to enter the main compressor. Filtration is also required to clear the ambient air before it is compressed. At the other end, an outlet valve is the release point for the pressurised air, usually coupled with a pressure gauge.
The compression chamber is where the magic happens. Air is compressed using pistons or other methods before it is released.
Built-in sensors, gauges, and control systems allow for the management and configuration of the booster, as well as pressurisation levels and flow rates.
Benefits of Using Compressed Air Boosters
Targeted Pressure
Boosters increase air pressure only where needed. Most machinery at Wilson’s Manufacturing works fine at 7 bar, but their testing rig needs 40 bar. They installed a small booster next to the testing bay rather than upgrading their entire system.
Energy Use
Boosters typically use less power than running a large high-pressure system. The Cooper’s Brewery in Manchester only runs its booster during the Thursday bottling shift. It sits unused most of the week, keeping the electricity bill lower.
Equipment Lifespan
Using a booster means your main compressor does not work as hard. The maintenance manager at Blackwell’s Plastics told me they have had their primary compressor since 2012 but only added the booster in 2019. The main unit runs cooler now and needs fewer repairs.
Adaptable Setup
Boosters fit into most existing systems. Barton Engineering bolted theirs to the floor next to the paint spray booth. They ran some extra pipe along the wall and connected it with standard fittings. The whole job took a day and a half.
Safety Considerations
Keeping lower pressure in the main system reduces risks. Wilson’s workshop in Sheffield marks their pipework with coloured tape: blue for standard pressure lines and red for the boosted sections that feed the cutting equipment.
Installation and Maintenance Tips
An air booster is ideally placed within an air compressor system after the compressor but before the cooling system. This permits the increase in air compression and the heated air to be cooled down significantly before reaching the outlet valve. This approach also avoids potential pressure losses. Monitoring air release at the right air pressure via a pressure gauge is best.
No matter how new your air booster is, scheduled maintenance is required. This includes replacing worn seals, valves, and filters. Wear, dirt, and clogging all impact these respective parts. Early replacement avoids unnecessary operational failures.
Discuss with J LL Leach how they can help with a planned maintenance package for your air compressor system.
Pro Tip: Engage in a planned maintenance package with experienced service providers, such as J LL Leach, to minimise downtime and ensure long-term reliability.
Common Applications of Compressed Air Boosters
Compressed air boosters are required in various industries, applications, and situations. Low air pressure is often insufficient for the planned activities.
Here are a few of those types of situations:
Manufacturing: packaging, PET blowing, laser engraving, and many other applications within the manufacturing sector are relevant. These require 20 or 40 bar, which is beyond the specification of a standard air compressor.
Automotive: parts assembly and painting/respraying depend on pressurised air for pneumatic air tools and paint spray guns. Continuous high pressure is required, or the air tools will not function.
Power plants/energy sector: plants experience situations where necessary pressure levels exceed 50 or 100 bar. High-end air boosters solve this.
Choosing the Right Compressed Air Booster for Your Needs
When choosing an air compressor system, it is essential to consider both the expected pressure levels and the typical flow rate. This assessment quickly confirms whether one or more compressed air boosters are necessary within the system.
Even often overlooked aspects, such as the ambient temperature inside the plant or peak humidity levels, require consideration.
Failure to use a properly configured air system leads to unanticipated issues, such as an inability to deliver high enough pressure or at a sustained flow rate to satisfy all operational needs.
Talking with air compressor experts is necessary to obtain a properly configured system that is fit for purpose.
Pro Tip: consult air compressor experts to configure a system tailored to your operational demands and ensure optimal performance.
Conclusion
Air boosters are vital for numerous air compressor systems. Without one, higher air pressure levels are unobtainable or extremely limited. Boosters deliver targeted pressure levels, reduce overall energy consumption, and improve the longevity of your equipment.
Discuss your compressed air requirements with our team at J LL Leach. We can determine whether boosters are required in your air system.
FAQ
What is the purpose of a compressed air booster in an existing system?
A compressed air booster is used to increase the pressure of already compressed air within an existing system. Its primary purpose is to supply higher pressure to specific tools or processes without the need to upgrade the entire compressed air infrastructure.
Can a booster system improve energy efficiency in industrial applications?
Yes, a booster system can significantly improve energy efficiency in industrial applications. Instead of increasing the pressure across the entire compressed air system, which demands more energy and leads to higher operational costs, a booster allows you to deliver higher pressure only where and when it’s needed.
Is it possible to use compressed air boosters for both air and gas?
Yes. Many compressed air boosters are designed to work with both air and gases such as nitrogen. These boosters can increase the pressure of both compressed air and inert gases, making them versatile for a range of industrial applications.
It’s important to ensure the booster is compatible with the specific gas in use, especially when working with high-purity or reactive gases.
