A breath of fresh CompAir
September 21st 2005

Having just celebrated its third birthday as a private company Ian Clay spoke to CompAir’ chief executive Nick Sanders. Here he discovered the influences and thoughts behind the company’s new range of products as unveiled recently in Simmern, Germany

The recent history of CompAir while not exactly a ‘phoenix from the flames tale of daring do’ is definitely one of a company halting a decline and putting in place a strategy for a successful future. A strategy which is now bearing fruit and accelerating forward.

One of the key factors in this reshaping of the business, as identified by chief executive Nick Sanders is the development of new products and technologies. “The company has” says Nick “put alot of effort into the engineering side...the breadth and depth of the product range has definitely been improved”. Indeed, during the last couple of years CompAir has developed more new products than in the previous five years of the company’s history. The biggest developments have been the Hydrovane and oil-free ranges which have found strong favour amongst users. CompAir is not resting on its laurels either as it proved with the launch of a raft of new and improved products at its facility in Simmern, Germany, all products exhibited characteristics of the new CompAir mantra “designed for production.”

Energy efficiency - fact or fiction?

Nick Sanders firmly believes that energy costs are becoming a real factor in the purchase of compressed air equipment after years of lip service. “As the oil price has continued to rise so the penny has finally dropped” says Nick. With the rise in price of utility costs so financial directors are looking to replace equipment due to energy consumption rather than just due to the fact that it has reached the end of its useful life. “This fact” says Nick “plays right to our sweet spot” as can be seen with the announcement at Simmern that the entire oil free range now has variable speed as an option.

CompAir’s range of oil free compressors has been strengthened with the addition of two new water injected screw compressors. These are switch reluctance variable speed models. Designed for applications where there is a need for high quality ‘oil free’ air, this range offers a cost effective oil-free solution. The system uses a digitally controlled switched reluctance DC drive. The drive system enables the compressor to match output to varying demands and as a result saves energy. Adding an SR compressor (i.e. with a drive which CompAir manufactures under license from SR Drives) to any installation of standard oil free compressors gives the system the ability to match output to demand.

Simmern also saw the announcement that the smaller compressors will also benefit from variable speed controls. The previous oil free series included 15, 22 and 37kW models which were all fixed speed but now new variable speed models mean the final oil free range extends down to 15kW and up to 75kW.

Graham Roberts, managing director of the Industrial Division explained: “In active air applications, quality of the air is key. High technology industries all demand higher quality air. They are also looking for the lowest ownership and operating costs. A major advantage of this design is that not only is the air produced totally oil free, there is no oil used in the compressor at all. The bearings are greased and sealed for life, so there is no danger of contamination and no environmental costs associated with oil disposal.”

Market forces

As well as the demand for energy efficiency modern conditions demand that compressors have a small footprint and are low maintenance. CompAir has introduced five new models to its L-Series screw compressor range – including increased numbers of speed regulated models. The first new models are the L55-75F. These models boast an integrated dryer after the company found that it was often installing a dryer alongside existing products. The combined units has numerous benefits. The compressor/dryer has a smaller footprint and it also has just one controller. This makes using the compressor and dryer a simpler task. Plus the integrated unit is easier to install and maintain. The dryers used are able to reach the necessary 3° dewpoint at an average ambient temperature of 25°C. The dryers components are standard and reliable parts, efficiently arranged so that inspection and servicing can be carried out easily and quickly.

A third innovation is the new L75SR that has a 3-phase SR drive that increase the output of air (when compared to the older model) by 12%. The compressor has an increased protection class of IP55 meaning higher reliability for the end user, even in polluted areas. The new SR drive is also being used as part of the L75FSR that can combine the variable speed opportunities with the integrated dryer in one simple unit which offers the same energy efficiency and output of the L75SR but with the added benefits of an integrated dryer.

The new models also have the updated DELCOS 3100 controller. Enhancements include an increase in programme capacity that enables 17 languages to be incorporated and flash programmability so programme updates can be implemented via the RS485 port. New features include the maintenance interval counter for motor bearing regreasing, the unlimited automatic restart after power loss and the direct communication and power link to the dryer unit.

The shape of things to come

As has been discussed earlier, one of the main reasons for CompAir’s recent revival has been the increase in speed of its new product development. This is set to continue apace as at the Simmern event the company announced the launch of even more new products that are due to go into production during the next eight months to extend its range of oil lubricated compressors further.

The company’s Simmern facility has played host to the announcement of new preview models including the L30, L37 and L45 fixed speed compressors, that are due to be available at the end of the year. CompAir has also announced that during the next few months they will bring to market a new L45SR, incorporating the new 3-phase SR Drive that increases the output of air by 10%. The new models will enter production in the coming months and will be available for sale in the European market by the end of the year. This means that CompAir will then offer an integrated dryer solution from 7.5 to 75kW and a speed regulated range from 45 to 250kW.

Right here, right now

With the launch of the above new products (plus the announcement of those yet to be launched) all engineered to meet the demands of today’s manufacturing environment CompAir seems well set to continue its successful recovery. Nick Sanders, chief executive is bullish about how successful these new products will be describing them as “Right here, right now” products that will benefit users today.

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