According to Dino Alessio, marketing manager at Champion Compressors, there is a disturbing trend towards offering seemingly attractive air packages, by extending servicing periods. Contracts recommending 3000-hour intervals between services are not uncommon, and customers should be aware of the countless hidden costs. While at surface value 3000-hour services may make an attractive offer, delayed maintenance checks make machinery susceptible to increased power consumption and reduced life cycles.

Alessio cites the check-up of a 15-kW air compressor, which after 1500 hours of operation reveals a clogged oil filter worth an estimated $50. “If left unattended for a supplementary 1500 hours, the clogged filter will cause an increase in energy needs to compress the oil through the channel. Should the oil ultimately be forced to bypass the filter altogether, unfiltered oil will deposit dirt and foreign material directly onto the bearings, coolers and oil separator. The greater restriction in the oil separator could equate to a $100 increase in power costs over the period,” said Alessio. “This could also lead to the need for an air-end overhaul priced at around $2000 for a compressor of this rating--not to mention the costs associated with downtime,” he added.

In a similar case, an undetected blocked air inlet left for a 3000-hour period will cause a pressured drop of 12 to 13 kPa, equivalent to a $270 increase in power costs over 1500 hours. Again, this could shorten the life of the rotary screw air-end.

“Doing a steady 60 km/h in your car for 1500 hours you would cover 90,000 km--would you consider it safe to drive your car an extra 90,000 km between services?” asked Alessio. Clearly, air compressors, just like cars, require regular servicing. “When considering an air package, the decision should be made based on lifetime costs, not merely the air compressor’s purchase price and basic service cost--which represent only three to four per cent of the total,” said Alessio.