Understanding High-Pressure Air Compressors

Used in a wide range of industries, high-pressure air compressor solutions are used in applications that require consistently high pressure and additional pounds per square inch (psi) — generally around 650 psi or higher — to complete certain tasks. Compressor boosters are also available to serve as add-ons for existing systems.

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At Compressed Air Systems, we often field questions about the different types of high-pressure systems and their specific properties and benefits. Below, we’ve addressed some of the most frequently asked questions.

How Do High-Pressure Air Compressors Work?

There are two main types of compressors falling under the high-pressure category: standard high-pressure air compressors and high-pressure booster compressors.

Complex and versatile, high-pressure air compressors take ambient air through several stages of compression in order to supply a consistent pressure of up to 6,000 psi. The air is cooled as it moves through each stage in order to compress as much as possible. This allows for optimal amounts of pressure.

High-pressure booster systems, on the other hand, require standard pressure services and inlets of at least 125 psi to allow for discharge pressure ranges of 450 to 640 psi. Using pre-compressed air from existing systems, these add-ons are built for specific points of use; they’re most often used in situations in which plant service air is needed for most services but much higher pressures are required for others.

Most industrial plants are able to handle pressures between 90-100 psi, so boosters are critical for completing many industrial tasks; these serve as cost-effective alternatives to outfitting the entire plant for higher pressures. PET plastic blow molding, for instance, requires very high pressures, so plants may use a booster system to enhance existing systems used for other applications, most of which won’t require nearly as much pressure.

Comprehensive, high-quality compressor systems will also feature controls allowing for automatic filling and remote monitoring, which, in turn, allow for integrated plant-wide monitoring systems. Any issues can then be quickly identified and remedied.

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When Do You Need to Use It?

Many air compressing jobs require 6,000 psi or greater — far above the pressure range of most standard systems. Designed for use in any application requiring 650 psi or more, high-pressure air compressors (or, in certain applications, boosters) allow for a consistent supply of high pressure.

In sensitive applications like SCUBA or SCBA, for instance, maintaining a constant, reliable high pressure is critical to ensure users are provided with as much breathing air as possible from a single tank.

What Makes Up a High-Pressure Air Compressor System?

High-pressure compressor systems are comprised of an air compressor, fill stations and tanks, and cylinder fill stations. These systems can also supply air to a cylinder bank, allowing for air supply in peak-demand situations, in which pressure greater than that which the compressor is capable of handling is needed for a limited amount of time.

Both complete air compressor systems and boosters include multi-stage intercoolers to allow for optimal cooling between each step of the process, ensuring optimal pressures are created.

Where Can I Purchase?

To ensure consistent, reliable pressures for your application, it’s critical to partner with a knowledgeable provider who can assist you in the selection process and work with you through any questions or issues you may have.

Since , Compressed Air Systems has been providing air compressors, blowers, vacuums, and nitrogen generators, and process chiller equipment to companies in critical industries, including food processing and aerospace. Our food-grade compressed air solutions are compliant with the FDA’s Food Safety Modernization Act, and our compressed air for aerospace applications meets the strict regulations of this industry. We also offer audit services, rentals, and turnkey solutions.

Whether you are looking for a quick diagnosis and repair or a full turnkey system, we are the ideal solution provider for all your compressed air needs. Read on to learn about high-pressure air compressor systems and their applications.

Contact us to discuss your requirements of High Pressure Air Compressor. Our experienced sales team can help you identify the options that best suit your needs.

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High-pressure industrial air compressors take in ambient air and compress it to pressures up to pounds per square inch (PSI). The air flows through several compression stages and is cooled after each one so that it can be compressed to high pressures. Industrial high-pressure air compressors can achieve compressed air between and PSI.

Examples of applications that use high-pressure air compressors include the industrial, paintball, fire, and SCUBA markets. Before purchasing an air compressor for your facility, you must consider factors such as type of usage, space requirements, and cost. At Compressed Air Systems, we carry a broad selection of high-pressure air compressor systems to meet your budget and performance specifications.

The components of a high-pressure compressed air system include fill stations, cylinder fill stations, tanks, and an air compressor. The system can also deliver air to a supply bank to provide compressed air during peak-demand situations, which demand more pressure than a compressor can handle. A complete high-pressure air compressor system and boosters will have multistage intercoolers to optimize cooling between the steps of the process, creating optimal pressures.

Breathing air is purified and compressed atmospheric air. It meets certain standards for contaminants and does not undergo enrichment. Breathing air provides a lifeline in critical situations like SCUBA diving and firefighting. Compressor Air Systems has compressor modules that can integrate into your existing systems to ensure reliability for all your breathing air needs.

RECREATION

The recreational applications of high-pressure compressed air include paintball and precharged pneumatic (PCP) air rifles. The compact canisters usually contain - PSI.

INDUSTRIAL HIGH-PRESSURE AIR

High-pressure air is crucial in the industrial sectors for various applications, including air blast circuit breakers, pneumatic and hydraulic system leak testing, blow molding, proof and leak testing in refrigeration heat exchangers, and valve testing. It’s also a cost-effective replacement for high-pressure nitrogen.

Furniture Manufacturing

Furniture manufacturing requires high-pressure compressed air for power tools, actuators, air piston power, clamping, and spraying.

Metal Fabrication

Several metal fabrication processes, such as injection molding, spraying, and tooling, require high pressure air.

Food & Beverage

Several applications in the food and beverage industry require high pressure, such as dehydration, cleaning, conveying, spray coating, bottling, and vacuum packing.

Mining

Examples of tools that require high pressure in the mining industry include hoists, pumps, actuator controls, and pneumatic tools.

Plastics, Silicone, & Rubber Manufacturing

Compressed air powers tooling, mold press, clamping, forming, and injection molding operations in this manufacturing sector.

General Manufacturing

High pressure is crucial in general manufacturing applications such as clamping, tool cleaning, and stamping. It is also essential in power tools, controls, and actuators.

Breathing Air

Breathing air applications like SCUBA tanks for diving typically require tanks containing at least PSI. SCBA air packs are lighter, smaller, and easier to carry for hazmat and fire applications. They are available at , , and PSI.

Glass, Stone, & Clay

The glass, stone, and clay industries use high pressure air for mixing, blending, conveying, molding, and cooling.

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