How to properly size industrial air compressors for your facility

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Investing in an air compressor is a big decision that can greatly improve the productivity of your business.

The question is how to choose the right compressor size for your needs. At Industrial Air Systems, we have three different approaches to this depending on your existing setup. We also take into consideration your requirements for CFM, air pressure, duty cycle, type of compressor, and more.

This article provides a step-by-step guide to help you determine the right compressor capacity for your business.

Sizing air compressors NZ

To ensure your air compressor is the correct size for your application, you need to work out the required air supply. Depending on your situation, there are three main ways to determine the right size for your air compressor.

1. Compare with an existing machine

If you are replacing an existing air compressor, check the kilowatt for a helpful baseline. If you want to adjust your air usage going forward, our compressed air experts can help you.

If your existing machine has a Programmable Logic Controller (PLC) controller, check the load and unload hours. This will indicate whether the machine spends more time working or idling and help you identify over-cycling or inefficient usage. For more information, read our article about upgrading your air compressor.

2. New factory

If you have a new factory or industrial setup, you will need to identify the air volume and required pressure on all your machinery. Based on your air usage and end-use equipment, our experts can calculate the total air demand figure and recommend a compressor size that can meet this. We will also discuss how to accommodate future growth.

3. Upgrading your air compressor

If upgrading an existing plant, you can fit a datalogger or flow meter into the air compressor system. This will gather data on your air usage and determine the correct size compressor accordingly.

Key considerations when sizing air compressors

CFM Requirements

The CFM measures the volume of air a compressor can deliver. To calculate your total CFM requirement, add up the peak air consumption of all your end-use tools. Remember to account for periods when all tools are operating simultaneously.

Pressure Needs (PSI)

Find the highest PSI rating of all your tools and choose an air compressor that can match this. If your tools need different pressure levels, consider using pressure regulators to manage them.

Duty Cycle

Think about the duration and frequency of air demand in your workshop. Will the new air compressor keep up with this without overheating? For continuous use, a duty cycle close to 100 will be needed.

Reciprocating compressor vs rotary screw compressor

A reciprocating compressor will usually be the most suitable for low to medium air demands. For continuous use or high-volume air demand, a rotary screw compressor will be more efficient.

Air Receiver Tank

A larger air tank stores compressed air, helping to reduce how often the compressor needs to run. Generally, the tank size (in gallons) should be approximately one-quarter to one-third of the CFM output.

Electrical Requirements

We also recommend assessing your facility’s electrical system. This will help you determine if it can handle the air compressor’s power requirements, such as voltage, phase, and amperage.

Future expansion

When choosing an air compressor, it is worth preparing for any future growth in your operations. If you anticipate a change in your air demand or the tools you’re using, we recommend opting for a compressor with a higher capacity than you currently need.

Additional factors

Finally, account for the air compressor’s environment because the ambient temperature and humidity can impact its performance. We also advise that you install the air compressor for easy accessibility, enabling maintenance and servicing as required.

Upgrade your industrial air compressor NZ

At Industrial Air Systems, we supply all the compressed air equipment you need, including:

Air compressors NZ

We are New Zealand’s leading supplier of rotary screw compressors, along with our wide range of other air compressors. With decades of industry experience and our world-class PneuTech technology, you can trust us to equip you with the best compressed air solutions.

Whether you need a large air compressor, a 70 cfm air compressor, or compressed air that meets Class-0 Certification, we have the solution for you.

Browse our full range of Air Compressors >>

Workshop air compressor equipment

We also supply and service a range of equipment for your air compressor system. We also offer engineering and compressor services for all our products, keeping your plant running at the most crucial times.

For more information and recommendations, download our Air Compressor Brochure.

Learn more about our Air Compressor range

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