Industrial facilities depend on reliable compressed air and electrical power to keep production moving. From powering pneumatic tools and automated equipment to supporting backup electrical loads, the right equipment can affect productivity, operating costs, and equipment performance.

When comparing rotary screw air compressors, compressed-air dryers, and diesel generators for North American operations, equipment specifications should be evaluated alongside documented facility requirements and application-specific operating conditions.

MasterAire provides industrial power and compressed-air solutions for businesses across North America. Available equipment categories include industrial air compressors, industrial generators, and refrigerated air dryers for commercial and industrial applications.

This guide outlines how these systems operate, their typical applications, and the factors involved in preliminary equipment selection.

Industrial equipment rarely operates in isolation. A manufacturing plant, repair facility, warehouse, or processing operation may rely on several connected systems.

An industrial air compressor generates compressed air. A dryer removes moisture from that air before it reaches downstream equipment. Electrical systems supply power to compressors, dryers, production equipment, controls, and other facility loads. A generator may provide standby or prime power depending on the application and generator rating.

This means equipment selection should start with the system as a whole.

Key questions include:

• How much compressed air does the facility require?
• What operating pressure is needed?
• Does air demand stay relatively constant or change throughout the day?
• What air quality and pressure dew point are required?
• Which electrical loads must remain operational during an outage?
• What are the expected operating hours and duty requirements?
• Are future production increases likely?

Answering these questions can help narrow the available options before comparing individual models.

Compressed air is sometimes described as a fourth utility because of its importance in industrial operations. It can power tools, actuators, controls, production machinery, material handling equipment, and many other processes.

An industrial air compressor converts mechanical energy into compressed air and supplies that air to a facility's distribution system.

Common applications include:

• Manufacturing and assembly
• Automotive repair and service
• Metal fabrication
• Packaging operations
• Food and beverage processing
• Warehousing
• Woodworking
• Construction support
• Industrial maintenance
• Pneumatic automation

Different applications have different air demand profiles, which is why compressor selection should be based on more than horsepower alone.

A rotary screw compressor uses a pair of meshing helical rotors to reduce the volume of trapped air and increase its pressure. The rotary compression process supports relatively steady airflow.

Many industrial rotary screw air compressors are designed for high-duty or continuous-duty applications, subject to the model’s rated operating conditions.

Depending on the model and configuration, advantages can include:

• Suitability for sustained industrial operation
• Consistent compressed air delivery
• Compact equipment layouts
• Lower vibration than some reciprocating designs
• Options for integrated controls
• Multiple capacity and pressure configurations
• Oil-injected and oil-free configurations for different application requirements

Actual performance, efficiency, air quality, and duty capabilities depend on the compressor model, controls, operating environment, and manufacturer specifications.

When comparing available rotary screw air compressor models, horsepower and initial price should not be the only selection criteria. These specifications alone do not establish whether a compressor can meet the facility’s airflow, pressure, and operating requirements.

The preliminary equipment assessment should consider the following factors.

1. Determine Required Airflow

Airflow is usually measured in cubic feet per minute, or CFM.

The compressor should provide the required delivered airflow at the specified operating pressure while accounting for simultaneous demand, leakage, system pressure loss, storage capacity, future requirements, and an appropriate operating margin.

Oversizing can increase capital costs and may contribute to inefficient operation in some configurations. Undersizing can lead to pressure drops, inadequate air supply, and difficulty meeting peak production demand.

2. Confirm Operating Pressure

Pressure is typically measured in pounds per square inch, or PSI.

Identify the minimum pressure required at the point of use and account for pressure losses through piping, filters, dryers, and other system components.

Operating a compressor at unnecessarily high pressure can increase energy consumption. The goal is to provide the pressure the process actually needs while accounting for reasonable system losses.

3. Understand the Demand Profile

Does compressed-air demand remain stable throughout a shift, or does it fluctuate with production activity?

This distinction can influence compressor configuration and control strategy.

A facility with stable demand may have different requirements from one with frequent production changes. Variable-speed-drive compressors can be useful in some applications with fluctuating demand because output can adjust with changing air requirements.

Whether a variable-speed or fixed-speed design is more suitable depends on the actual load profile and operating conditions.

4. Consider Duty Requirements

Duty cycle indicates the percentage of a defined operating period during which a compressor is designed to operate under specified conditions. Facilities with extended production shifts require equipment suited to their expected operating patterns. Compressors with similar horsepower ratings may have different duty-cycle ratings and operating limitations. The manufacturer’s published specifications should be reviewed for the specific model and expected load conditions before equipment selection.

5. Plan for the Operating Environment

Temperature, ventilation, dust, humidity, altitude, and installation space can affect compressor operation.

Adequate ventilation is particularly important because air compressors generate heat. Installation requirements vary by model, so manufacturer clearance and environmental specifications should be incorporated into facility planning.

Producing compressed air is only part of the process.

Atmospheric air contains water vapor. When air is compressed and subsequently cooled, moisture can condense within the compressed air system.

Without proper treatment, moisture may contribute to:

• Corrosion inside piping
• Problems with pneumatic equipment
• Product contamination in sensitive processes
• Reduced reliability of downstream components
• Additional maintenance
• Water accumulation in distribution lines

A compressed air dryer helps reduce moisture before compressed air reaches downstream equipment and processes.

Compressed-air dryer selection should consider required airflow, inlet conditions, ambient conditions, air-quality requirements, and pressure dew point.

Pressure dew point indicates the temperature at which water vapor begins to condense at system pressure. Applications with stricter moisture requirements generally need a lower pressure dew point.

Two common dryer technologies are refrigerated and desiccant dryers.

Refrigerated Compressed Air Dryer

A refrigerated compressed air dryer cools compressed air so water vapor condenses. The condensed moisture is then separated and drained before the air continues into the distribution system.

Refrigerated dryers are commonly used for general industrial applications where extremely low pressure dew points are not required.

Potential applications include:

• General manufacturing
• Automotive facilities
• Pneumatic tools
• Packaging operations
• Fabrication shops
• General plant air

A refrigerated dryer can provide a practical balance between moisture control and operating requirements for many facilities.

Explore MasterAire refrigerated air dryers.

Desiccant Air Dryers

A desiccant industrial air dryer uses a moisture-absorbing material to remove water vapor from compressed air.

These systems can achieve lower pressure dew points than typical refrigerated dryers, making them suitable for applications with more demanding air quality requirements.

Potential applications can include:

• Instrument air
• Certain process applications
• Cold environments where condensation or freezing is a concern
• Sensitive manufacturing
• Applications requiring very dry compressed air

Dryer selection should be based on the required pressure dew point rather than assuming one technology is appropriate for every application.

A dryer needs to handle the actual operating conditions of the compressed air system.

Important factors include:

• Compressor airflow
• Operating pressure
• Compressed air inlet temperature
• Ambient temperature
• Required pressure dew point
• Expected peak airflow
• Dryer correction factors
• Future compressed air demand

A dryer that appears correctly sized based only on nominal CFM may not provide the required performance when actual inlet or ambient conditions differ from its rated conditions.

The manufacturer’s sizing data and correction factors should be reviewed for the proposed operating conditions.

Where Should a Compressed Air Dryer Be Installed?

System layouts vary, but dryers are generally integrated with other air treatment and storage components such as aftercoolers, moisture separators, filters, receivers, and drains.

The correct arrangement depends on dryer technology, compressor configuration, and required air quality.

A properly designed compressed air treatment system should consider the entire air path rather than treating the dryer as an isolated component.

Electrical outages can interrupt production, refrigeration, pumps, communications, controls, lighting, data systems, and other important facility operations.

For organizations evaluating diesel generators for North American operations, equipment selection should begin with the load profile and intended operating duty.

A diesel generator combines a diesel engine with an alternator to generate electrical power. Depending on its rating and configuration, it may be used for standby, prime, or other approved applications.

MasterAire offers industrial generators for commercial, standby, prime-power, and other approved applications.

Diesel generators are used across a wide range of sectors, including:

• Manufacturing plants
• Warehouses
• Construction operations
• Commercial facilities
• Agricultural operations
• Telecommunications
• Data and communications infrastructure
• Industrial processing
• Remote operations
• Emergency and standby power systems

The appropriate generator depends on the load profile, operating environment, electrical requirements, duty rating, and applicable installation requirements.

Selecting an industrial diesel generator involves more than adding up the wattage or kilowatt ratings of connected equipment.

Several factors should be evaluated.

Calculate Running Loads

Identify equipment that needs to operate when the generator is supplying power.

Examples may include motors, compressors, pumps, lighting, controls, HVAC equipment, refrigeration systems, and production machinery.

Account for Starting Demand

Electric motors can require significantly more power during startup than during normal operation.

Pumps, air compressors, HVAC equipment, and other motor-driven loads may create short periods of higher demand.

Simultaneous motor-starting events can significantly influence generator sizing and transient performance. Motor-starting methods, load sequencing, variable-frequency drives, and soft starters should be evaluated according to the application. Compatibility, harmonics, and manufacturer requirements should also be considered when electronic motor controls are used.

Understand Generator Ratings

Generator sets may be assigned standby, prime, continuous, or other manufacturer-defined ratings based on their intended operating conditions.

These terms describe different intended operating conditions and should not be treated as interchangeable.

A standby generator designed for emergency backup service may have different operating limitations from equipment rated for prime power.

Equipment selection should follow the manufacturer’s published rating and intended operating application.

Consider Site Conditions

Generator performance and installation can be influenced by:

• Ambient temperature
• Altitude
• Ventilation
• Fuel storage
• Exhaust requirements
• Noise restrictions
• Weather exposure
• Required clearances
• Local codes and regulations

Generator output may require derating under certain environmental conditions. Manufacturer specifications should be reviewed for the proposed installation conditions.

When evaluating available industrial diesel generator models, selection should consider factors beyond stated kW output and initial purchase price.

Consider:

• Standby, prime, or continuous rating
• Voltage and phase requirements
• Frequency
• Engine and alternator specifications
• Control system
• Enclosure requirements
• Fuel tank configuration
• Sound attenuation
• Service accessibility
• Parts availability
• Maintenance requirements
• Warranty coverage
• Site installation requirements

For a commercial diesel generator, also consider which facility loads actually need backup power. Not every electrical load necessarily needs to operate during an outage.

Prioritizing critical loads may reduce the generator capacity required while still supporting essential operations.

These equipment categories perform different functions, but they may all contribute to facility reliability.

A compressor creates the air supply. The dryer improves compressed air quality by reducing moisture. The generator supplies electrical power when its designated operating conditions require it.

In some facilities, these systems may also interact. For example, a generator selected to support an air compressor during a utility outage must account for the compressor's electrical running demand and motor-starting characteristics.

A reliable industrial system begins with accurate operating data.

Before equipment selection, document the facility’s current operating requirements.

For Compressed Air

Record:

• Required CFM
• Minimum operating PSI
• Peak demand
• Average demand
• Operating hours
• Air quality requirements
• Pressure dew point requirements
• Existing storage capacity
• Expected future demand

An air system audit can provide additional insight into demand patterns, pressure losses, leaks, and opportunities for system improvement.

For Electrical Power

Record:

• Running kW
• Starting loads
• Voltage
• Phase
• Frequency
• Critical loads
• Load sequencing
• Expected generator runtime
• Required duty rating
• Site and environmental conditions

This information provides a stronger basis for equipment selection than choosing capacity from a general rule of thumb.

Before equipment selection, the factors that may affect long-term system performance should be evaluated.

Evaluate verified operating demand. Equipment should not be sized solely from nameplate horsepower. Actual airflow, operating pressure, electrical demand, and system conditions should be assessed.

Account for documented future demand. Planned equipment additions and facility expansion should be incorporated into the capacity assessment without automatically oversizing the system.

Evaluate the complete system. Piping, filtration, air storage, dryers, electrical distribution, ventilation, and controls can influence overall system performance.

Confirm installation requirements. Equipment placement should account for space, ventilation, service access, environmental protection, and manufacturer-specified clearances.

Evaluate maintenance access. Filters, drains, coolers, lubricants, belts, batteries, and other service items should remain accessible.

Confirm model-specific specifications. Equipment with similar stated ratings may have different operating limits, controls, configurations, and performance characteristics.

Industrial equipment selection requires an evaluation of airflow, operating pressure, air quality, pressure dew point, electrical load, starting demand, duty rating, site conditions, and anticipated future capacity requirements.

MasterAire supports businesses across North America in evaluating industrial air compressors, compressed-air dryers, and generator options based on documented facility requirements and application-specific operating conditions.

Explore MasterAire air compressors, refrigerated air dryers, and generators. Contact the MasterAire team to discuss available equipment configurations and operating requirements.