How Can You Extend the Life of an Air Compressor?

Air compressors play a vital role in homes and industries worldwide, powering pneumatic equipment in construction yards and inflating tires on racetracks. They rely on numerous components to carry out this work, but some components experience more wear and tear than others. Should these key parts break down, the compressor may slow down or stop working entirely.

Regular maintenance is the key to avoiding this fate and extending your air compressor's lifespan. In this article, we will walk you through the average lifespan of the most popular types of compressors and explore practical ways to extend that lifespan and maintain your compressor's performance.

The average life expectancy for a compressor varies based on a number of factors. These include:

• How often the compressor is used
• How the compressor has been handled and maintained
• The temperature, humidity and other environmental conditions around the compressor

Perhaps the most important factor, however, is the compressor's type. There are many different approaches to air compressor design, and each approach has resulted in a unique rate of air compressor depreciation. Here is how long each major type of air compressor lasts:

• Reciprocating/piston compressors: These compressors can last around 50,000 hours. Typically, that means you can expect to get 6 to 10 years out of them, depending on how they are treated and maintained.
• Oil-free rotary screw compressors: These compressors are not as long-lasting as their oil-flooded siblings, but they still boast a lifespan of 70,000 hours on average. This translates to approximately 10 to 15 years of use. The life expectancy of a rotary screw air compressor can be extended even further with consistent maintenance.
• Oil-flooded rotary screw compressors: With proper care, these compressors can last over 100,000 hours, which translates to a lifespan of 20 years or more.

Air compressor lifespan is variable, as the compressors themselves are not impervious to rust, decay and malfunction. This is where regular maintenance comes in. When properly cared for, air compressors can function at higher levels and last longer while requiring fewer repairs.

The 11 tips below are designed to help your air compressor do all three.

Not all air compressors use oil, but those that do need to have it checked and changed periodically. The oil lubricates, cools, cleans and generally supports the compressor's functions. 

However, it will eventually grow dirty or run low, meaning it will need to be replaced. Oil change timelines vary based on compressor type, but a good rule of thumb is to change your oil at least once a year. Checks should be conducted more regularly to assess oil levels and cleanliness.

Air compressor ventilation systems filter out contaminants in the air to protect the mechanisms inside the compressor. As a result, dust and dirt build up on the intake vent and filters over time, reducing the compressor's overall efficiency and power. Regularly checking these areas, cleaning the vent and replacing the filter will help prevent this problem and keep the compressor running smoothly.

Over time, the air receiver tanks inside the compressor accumulate moisture from the air that runs through the compressor. If these tanks fill, they may corrode and damage the systems around them. Manually draining these tanks regularly or installing automatic drain valves can prevent this damage and extend the compressor's lifespan.

Your air compressor's cooling fins keep it and the air it compresses from overheating. Gradually, these fins can slow and wear out as a result of dust and other contaminants. Wipe down the fins and clear any obstructions regularly to help your compressor stay cooler for longer.

Oil-flooded air compressors rely on an oil separator to prevent said oil from contaminating the compressed air and the filters around it. The separator uses centrifugal force and intense pressure to achieve this separation, but over time, the separator weakens and cannot generate the same pressure. This pressure drop will make your compressor burn through oil quicker and lead directly to increased energy costs.

As such, it is important to replace your oil separator periodically to keep it operating at peak capacity. Your specific compressor's specs can offer insight into when exactly you should make this change, but it should fall somewhere between 2,000 and 8,000 hours.

Cracks can emerge in your air compressor's hoses over time or as the result of an accident or malfunction. These cracks can cause everything from coolant to compressed air to leak from the compressor. Regular visual inspections can help you spot and replace these cracked hoses before they become a problem, saving you from increased energy costs and decreased power and efficiency.

Air compressors vibrate and shake in the normal course of operations, and over thousands of hours, this shaking can loosen hoses, bolts and other connections. In extreme cases, these loose connections can damage the compressor and result in costly repairs. As such, be sure to regularly inspect and tighten any connections that have loosened over time.

Air compressors come with standard operating temperature ranges that they should stay within. Straying from these ranges can cause the entire system to overheat and burn through its lifespan at an accelerated rate. Proper compressor placement and ventilation can help mitigate this issue, but you should still regularly check the operating temperatures and make adjustments and repairs accordingly to keep your compressor in the green.

Air compressors that rely on oil can't just use any oil you come across in an auto parts store. They are only compatible with oils that are designed for use with their specific model, so it is important to check the user manual or contact the manufacturer for information on which lubricants are viable. Then, you can replace the oil without fear of damaging the compressor.

When repairing your compressor, it can be tempting to just purchase the part nearest to you and hope it works. In the long term, however, this approach can significantly reduce the compressor's lifespan and lead to malfunctions and other problems. Instead, use parts that come directly from the compressor's manufacturer or parts that they recommend. This may slow repair times in some cases, but it will result in higher efficiency and a longer lifespan overall.

Despite your best efforts, some wear will likely escape your notice. A problem with the compressor's motor or another component might have led to an invisible inefficiency draining your energy and your wallet. An air compressor audit can help you identify issues like this so that you can repair the compressor or upgrade your network and ensure you're not spending extra money unnecessarily.

The audit is typically carried out by an engineer with access to compatible data-logging units. These units evaluate your compressor's power consumption, air pressure and more. To keep a close eye on your compressor's overall health, you should try to have an audit completed every three to five years.

Repairing and auditing an air compressor can be a complicated business, but partnering with Chicago Pneumatic makes things quick and simple. For us, it's all about people, passion and performance. We offer compressor service kits and other parts designed to get your machine up and running like new. All of our air compressor products are tested and verified by the Compressed Air and Gas Institute to ensure their quality, and our customer service is just as reliable.

To learn more about our parts and services, fill out our contact form or give us a call at 877-861-2722.