Oil-Free Air Compressors: The Pros, Cons & Alternatives

I work with and on many types of air compressors. Years ago, the medical field, scuba diving, and air exchange like mine shafts and sewer systems would be the only oil-free compressors to be found. Oil-free became oil-less Air Compressors and started popping up for home use. The advantage mainly was fewer parts and more compact resulting in a lower affordable cost. Unfortunately, they were garbage! Homeowners may get a few years of use from an oil-less compressor but avoid using it because it was so loud. Professionals hated them. They didn&#;t last, It would shake across the floor, and the noise was unbearable.

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Flash forward to today&#;s quiet direct drive motor two-stage oil-less air compressor, and it is my goto on the go. Most of the tools I have, including an air impact, can be run from a small compressor for a short period. The lightweight all-in-one carrying frame is mobile.
Holding a conversation with it running next to you is not a problem, even with my hearing.

I have a single-stage oil-lubricated compressor at home. The added initial cost will pay off with trouble-free reliability, With an oil-less compressor, the cost would be approximately 20% less, and the decibels would be too loud to store it in my attached garage.

What are some pros and cons of oil-free air compressors?

5 Pros of an oil-less air compressor

1. lower maintenance to the pump.
2. fewer parts equal lower price.
3. smaller footprint
4. less energy consumption
5. weight is less than that of equal capacity

5 cons of an oil-less air compressor

1. The noise level of this type of compressor is louder at higher pressures.
2. dirty environments are catastrophic on oil-less compressors.
3. the duty cycle on these compressors is normally much lower.r
4. oil-less air compressors run hotter.
5. oil-less air compressors do not last as long.

How Does an oil-less Air Compressor Work?

Both types of compressors function much like your car&#;s engine,
Only without a spark plug and an exhaust stroke. The piston is pulled down, drawing in the fresh air, then is driven up, increasing the pressure. The main difference is the oil-less compressor uses permanently sealed bearings and synthetic gel lubricants.
The oil-less system doesn&#;t have an oil reservoir Eliminating oils from passing the pistons&#; rings and into the compressed air system.

Are Oil-less Air Compressors Better?

To answer this question, let us take a look at a comparison between two compressors on the market manufactured by the same company. Here you see a chart with a side-by-side comparison.

Please take note that the side-by-side comparison is not answering the question entirely.

oil- free compressor oil lubricatedWarranty2 years2 yearstank size27 Gal30Galdecibels(out side)80Db78Dbmax pressure 200 psi175 psihorse power1.7hp2.0 hpcfm @ 40psi5.1 cfm6.2 cfmcfm @ 90psi6.8 cfm7.7 cfmamp ratingweightcost at time of article
(both from same store)$399$499saftey data sheet neededno sheet neededyes sheet needed

At first glance of these two similar performing compressors the one hundred dollar cost of the oil lubricated compressor sticks out, the oil-less is only 2 decibels louder, one-half CFM, at 90 psi less than the competitor and lacks only point three horse power.

The biggest concern I have About larger oil-less compressors is Duty-Cycle, I have not seen Duty cycle ratings on any paperwork or online in quite some time. &#;Duty-cycle&#; is the amount of time the compressor needs to rest and cool compared to the amount of time it runs. an example of this is a 100% duty cycle rated compressor that will not need to shut off to cool it can stay cool and run non-stop, A 75% duty-cycle rated compressor can run for 45 minutes but then needs to cool off for 15 minutes before restarting. in the case of these two compressors, the oil-less has to work much harder when it turns on at 95 psi to get back to 200 psi. both compressors hold about the same volume of air. but the oil-lubricated compressor only has to reach 175 psi, which will equate to shorter run times and a longer life span.

Why Go With an Oil-Free Compressor?

We&#;ve talked about all of the benefits. Oil-less air compressors are cheaper than their oil-using counterparts. Because the oil-less compressor is smaller and lighter, it is more cost-effective to manufacture. The energy costs are also reduced because there is no need to collect and store oil-laden condensate. both types of compressors have their place, and I own both

Air compressors are essential for powering tools and machinery in our industries. As such, you must make an informed decision when selecting your next air compressor. There is a key factor to consider: do you go for an oil-lubricated air compressor or an oil-free one?

Each option has advantages and disadvantages so, as industry experts, we are dedicating this blog to help you make that decision. We will take a detailed look at each one allowing you to decide which is best suited to your business &#; saving you time and money in the long run.

Understanding Oil Air Compressors

Let us start with oil-lubricated air compressors. As the name suggests, these air compressors use oil to lubricate moving parts in the compression chamber. This helps to reduce wear while simultaneously cooling the system &#; so you end up with an air compressor that runs smoothly, without the risk of overheating.

Advantages of oil-lubricated air compressors 

• The main benefit of oil-lubricated compressors is that they are likely to have a long lifespan as the oil keeps the internal moving parts in good order. For your business, this means that you will save money on replacing your compressors in the future.
  
• If anything does go wrong with an oil-lubricated compressor, it will probably require less work to fix the problem &#; the issues tend to be simpler and easier to rectify.
  
• Oil-lubricated air compressors are ideal for heavy-duty work, especially in industrial settings.
  
• Finally, the oil used in this compressor type means that they produce less heat and are much quieter when they are in operation.

Disadvantages of oil-lubricated air compressors

Oil-lubricated air compressors will require routine maintenance, more so than is required with oil-free air compressors. You will need to check the levels of oil, and oil changes will be required. Each model will be different, so be sure to consult the manufacturer&#;s guide to establish how regular the oil changes need to be.

Best suited for

Oil-lubricated air compressors are generally used in industries that require heavy-duty use and where air purity is less critical. The automotive, construction, and manufacturing industries are perfect for oiled air compressors &#; they can run for long periods and have a greater air capacity so can be used to power larger tools. They are not advised for medical or food processing industries or any other industry where any air contamination could be harmful as the compressed air may have traces of oil.

Oil Versus Oil-Free Air Compressors Guide

Exploring Oil-Free Air Compressors

Now let us look at oil-free air compressors. Every type of air compressor will require some kind of lubrication, but oil-free compressors will either have pre-lubricated cylinders or utilise self-lubricating materials, which negate the necessity for oil. It is important to note that these compressors will contain some oil, they are not technically oil-free, but the crucial factor is that this oil will not come into contact with the compressor.

Advantages of Oil-Free Air Compressors

• One of the biggest advantages of having an oil-free air compressor is that it will require less maintenance as there is no need for regular oil changes.
  
• Oil-free air compressors also deliver air without any oil contamination risks &#; in many industries, this is of huge importance as any contamination could destroy the product.
  
• As a general rule, oil-free air compressors will be smaller, lighter, and therefore more portable than their oil-based counterparts. This is ideal if they are to be used at multiple sites.

Disadvantages of Oil-Free Air Compressors

• Oil-free compressors are likely to be more expensive up front, largely because the internal workings are more complex to avoid using oil.
  
• They also have a potentially shorter lifespan due to the lack of lubrication in heavy-use scenarios.
  
• An oil-free compressor tends to make a lot more noise than oil-lubricated compressors. You may need to consider whether this is going to be disruptive to other parts of the business.

Best suited for

Oil-free air compressors are best suited for use in industries where air purity is paramount. The medical, pharmaceutical, food processing, and electronics industries, which are sensitive to air contamination, are perfect for an oil-free air compressor (but they may not be the best choice for heavy-duty industrial use).

Oil Versus Oil-Free Air Compressors Guide

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Comparing Oil and Oil-Free Air Compressors

There are a few factors that represent the key differences between oil and oil-free air compressors, so let us break them down and consider them one at a time.

• Maintenance: Oil compressors will require more frequent maintenance, such as oil changes, while oil-free models require less maintenance.
  
• Cost: Oil-free compressors can be more expensive to buy, but you may end up saving some money on maintenance in the long run.
  
• Application suitability: Oil compressors are better for heavy-duty industrial applications, whereas oil-free compressors are better suited where air quality is crucial.
  
• Environmental impact: Oil-free compressors are more environmentally friendly due to less risk of oil spillage and contamination. They also tend to use less energy when in operation, as oil compressors need to move the oil through the compression chamber when in use.

Factors to Consider When Choosing an Air Compressor

There are a few key questions that you need to ask when choosing an air compressor.

• Application: How important is air purity for your operations? Will your new compressor be used for heavy-duty use?
  
• Maintenance capabilities: Does your business have the resources for the regular maintenance that oil compressors require?
  
• Budget: Can you afford the higher initial cost of an oil-free compressor? Is it justifiable for your operation?
  
• Environmental policies: Does an oil-free compressor align better with your company&#;s environmental commitments? Oil-lubricated compressors will also use more energy, which will have environmental consequences.

Maintenance Tips for Longevity

Whichever air compressor type you go for, you can do various things to increase your compressor&#;s longevity and avoid unnecessary maintenance costs. By following the guidelines below, you can keep your air compressor in the best possible condition and lengthen its life span.

• Always follow the manufacturer&#;s recommended maintenance schedule. There will be clear instructions about how often you need to perform various checks &#; make sure you put plans in place to ensure these checks happen. We offer Air Compressor Servicing which can save you a lot of hassle.
  
• If you have an oil-lubricated air compressor, make sure that you are regularly checking and changing the oil and filters. The frequency that you will need to change and check will depend on many different factors including the type of compressor you have and how often you use it. Make sure that you find out the best practices for your specific air compressor.
  
• If you have an oil-free compressor, remember to monitor for wear and tear on pre-lubricated parts. You may need to clean the air intake filters and conduct regular inspections of the hoses, power cables, seals, and fittings.
  
• Most air compressors will need to be stored in a clean, dry, location with a stable temperature. Find out what conditions your air compressor requires &#; this will help it to last longer without any impact on performance.
  

Applications and Industry Usage

The choice between oil-lubricated and oil-free compressors depends on the specific requirements of the industry and the intended application.

Oil-Lubricated Compressors

These compressors shine in industries where high power, durability, and reliability are paramount. Their ability to handle heavy-duty applications and operate in harsh environments makes them a preferred choice for:

• General Manufacturing: Oil-lubricated compressors are commonly used in manufacturing facilities for powering pneumatic tools, operating machinery, and providing compressed air for various processes. Their robust construction and ability to withstand continuous operation make them suitable for demanding production environments.
  
• Automotive Industry: Automotive repair shops and manufacturing plants rely on oil-lubricated compressors for tasks like tire inflation, paint spraying, and powering pneumatic tools. The high power and reliability of these compressors are essential for meeting the demands of the automotive sector.
  
• Construction Industry: Oil-lubricated compressors are frequently used on construction sites for powering pneumatic tools, operating jackhammers, and running other heavy-duty equipment. Their ability to withstand dusty and demanding conditions makes them a valuable asset in the construction industry.

Oil-Free Compressors

Oil-free compressors are indispensable in industries where air purity is of utmost importance. Their ability to deliver completely oil-free air makes them ideal for:

• Electronics Manufacturing: In the electronics industry, even the slightest trace of oil can damage delicate components and compromise product quality. Oil-free compressors ensure clean air, preventing contamination and ensuring the reliability of electronic devices.
  
• Pharmaceutical Industry: Compressed air is used in pharmaceutical manufacturing for various processes, including packaging, cleaning, and material handling. Oil-free compressors are essential to prevent contamination that could compromise drug safety and efficacy.
  
• Food and Beverage Industry: Oil-free air is critical for maintaining food safety and preventing spoilage. These compressors are used for tasks like packaging, aeration, and conveying food products, ensuring that the compressed air does not introduce any contaminants.
  
• Medical and Dental Facilities: In medical settings, oil-free air is used for various purposes, including powering surgical tools, ventilators, and dental equipment. The absence of oil contamination is crucial for patient safety and hygiene.

Understanding the specific requirements of your industry and application is key to selecting the right type of air compressor. By carefully considering the need for oil-free air or the demand for high power and reliability, you can make an informed decision that optimises performance and minimises risks.

Cost Implications

When choosing between oil-lubricated and oil-free air compressors, it&#;s important to consider not just the initial purchase price, but the total cost of ownership over the compressor&#;s lifespan. This includes upfront costs, ongoing maintenance expenses, and potential downtime costs.

Upfront Costs:

• Oil-Lubricated Compressors: Generally have a lower purchase price compared to oil-free compressors due to their simpler design and fewer specialised components.
  
• Oil-Free Compressors: Often have a higher upfront cost due to the more sophisticated technology required to achieve oil-free operation. This includes specialised air-end designs, filtration systems, and additional components to compensate for the lack of oil lubrication.

Ongoing Maintenance:

• Oil-Lubricated Compressors: Require regular oil changes, filter replacements, and maintenance of the oil separation system. These ongoing costs can add up over time, especially in high-usage scenarios.
  
• Oil-Free Compressors: Typically have lower maintenance requirements as they eliminate the need for oil changes and related maintenance tasks. However, they might require more frequent filter replacements and specialised maintenance for specific components.

Energy Efficiency:

• Oil-Lubricated Compressors: While generally reliable and powerful, oil-lubricated compressors are less energy-efficient than oil-free counterparts. The friction caused by oil lubrication and the need to cool the oil contributes to higher energy consumption.
  
• Oil-Free Compressors: Better energy utilisation due to the absence of oil-related friction and cooling needs. This translates to lower operating costs in the long run, especially in applications with high duty cycles.

Downtime Costs:

• Oil-Lubricated Compressors: Potential for downtime due to oil-related maintenance tasks like oil changes and filter replacements. Additionally, leaks or failures in the oil system can lead to unexpected downtime and costly repairs.
  
• Oil-Free Compressors: Generally, experiences less downtime related to maintenance compared to oil-lubricated compressors. However, they are not immune to breakdowns, and specialised maintenance might be required for certain components.

Overall, while oil-lubricated compressors might have a lower upfront cost, oil-free compressors often offer better energy efficiency and potentially lower maintenance costs in the long run. The specific cost implications can vary depending on the size, type, and usage of the compressor. It&#;s essential to carefully assess your specific needs and budget to make an informed decision.

Environmental Impact

Oil-free compressors are better for the environment, primarily due to the absence of oil in their operation. This eliminates the risk of oil spills, which can contaminate soil and water sources, harming ecosystems and wildlife. Additionally, oil-free compressors reduce the need for disposing used oil, a process that can pose environmental challenges.

On the other hand, oil-lubricated compressors have certain environmental challenges. The use of oil necessitates regular oil changes and disposal, which can contribute to pollution if not handled responsibly. Additionally, these compressors might have slightly higher emissions due to the energy required to compress air and cool the oil. Granted, modern oil-lubricated compressors are designed to minimise emissions.

In summary, oil-free compressors are more energy efficient compared to their oil-lubricated counterparts. This translates to reduced energy consumption, leading to a smaller carbon footprint and a more sustainable operation. By choosing oil-free compressors, businesses can contribute to environmental conservation efforts and reduce their impact on the planet.

Conclusion

When it comes to oil vs oil-free air compressors, only you will know what is best for your business. Both types of air compressors have valuable industrial applications &#; there is not one type that is better than the other, but there will be one that is more suited to your needs. Our job is to help you make the best decision.

Many businesses will make a quick decision and opt for the cheapest option if this saves them some money in the short term. They will probably end up with an air compressor with a shorter life span, and spend more on repairing and maintaining it. Do not make this mistake.

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