Bodyshop Compressor Advice

Ron Basciano, Automotive Manager, Atlas Copco Compressors, offers advice on choosing, installing and operating a bodyshop air compressor. In some bodyshop operators' view, the air compressor might be considered to be a necessary evil; equipment that is costly to buy and run and does not contribute directly to profits. But, realistically, it is at the heart of this business - without it, the bodyshop cannot function. That's why this following brief advice has been has been prepared. It is designed to help operators make the right decisions and to minimise the cost impact of an installation.

Sizing

The size of a compressor should be based, not on the total air using equipment, but on the usage factor at any given time. For example, there is no point sizing a compressor to run both a spraygun and a DA sander at the same time if only one person is working in the bodyshop. The rule is to size the compressor to the largest air-using equipment only. With the increased use of air drying for waterborne paints, there can be a corresponding greater demand for compressed air. However, again it is important to know whether a vehicle will be undergoing drying operations at the same time as a spraygun / air mask is being used. If not, there is no need to size the compressor to power both pieces of equipment.

Quality of Air

Because the risk of product spoilage, it is important to ensure the quality of the compressed air output and to be certain that it is sufficiently clean and dry. A drop of water or oil in the compressed air supply can ruin a paint finish. For this reason, the vast majority of new compressor installations now include a compressed air dryer and filtration components to ensure air quality before it is stored in an adequately sized air receiver. The location of the compressor will determine whether a refrigerant or a desiccant type of dryer is needed.

The bodyshop air supply also has to meet minimum standards for use with breathing masks. This quality of air is generally obtained by the use of belt-mounted filtration units and, for cost efficiency, this type of filtration will last longer if the incoming air is clean to start with.

Installation

With so much bodyshop equipment to accommodate it can be problematic sometimes to find space for it all. However, manufacturers, such as Atlas Copco, have designed compact packages that incorporate all this compressor equipment into one silencing canopy that is fitted on top of a horizontal air receiver and takes up less than 1 m2 of floor space. The added benefit of this standalone system is that the installation costs are lower overall as the individual items of equipment are pre-piped and pre-wired.

Air line pipework is less expensive than electrical cable so it is more cost-effective to site the compressor as near as possible to the electrical supply input.

For those who would prefer to install their own pipework but do not have pipe threaders, etc. for fitting galvanised steel pipe, help is at hand with the increasing availability of quick-fit aluminium pipe, such as Atlas Copco's AirNET, which is light, easy to fit and often less costly than its steel pipe equivalent.

Regulations

Nowadays there are many compressed air regulations to which users have to adhere. These are a couple of the most relevant ones:

• A motor rated electrical isolator of the correct size has to be mounted within 2 metres of the compressor and in the same room
• The condensate from the compressor must be cleaned before its disposal down the drains
For a complete professional overview and guidance on compliance with compressor installation regulations it is best to seek advice from a reputable supplier when considering compressor installation.

Energy Efficiency

The capital cost of a compressor package is comparatively low compared to the energy it will use over its lifetime. With the advent of Variable Speed Drive (VSD) compressors, the savings in electricity can be truly significant with pay-back time being comparatively short, depending on the usage. With VSD compressors, the air supply matches the air demand no matter how cyclical it may be. Reputable suppliers will be able to assess the likely savings to be achieved and advise accordingly.

The Carbon Trust, which is tasked with helping to reduce carbon emissions in industry, is able to advise on the financial help available to purchase energy-efficient equipment.

This is very brief insight into the areas to consider when purchasing a compressor. The best course of action is always call on the advice of a competent and reputable supplier to advise on such a valuable investment. Contacting a member of the VBRA is a very good start.