Air Compressors in the Food Industry: Pneumatic Solutions for Quality and Safety
December 13, 2023
Variable-Speed Vs. Fixed-Speed Air Compressors
December 27, 2023Stitching It All Together: Air Compressors in the Textile Manufacturing Sector
Kaishan USA | December 20, 2023 | Uncategorized
Today’s latest fashions all start with the textile manufacturing process, which relies heavily on air compressors and compressed air.
Air compressors play a significant role in the textile industry, powering the compressed air used not only to drive equipment, lift and transport textiles, but even to process, texture, dye and spin the textiles themselves during production.
Textile Industry Applications of Air Compressors
Compressed air provides textile manufacturers a clean, cost-effective source of power—a fourth utility (joining electricity, water and natural gas). By supporting a wide range of equipment and processes, compressed air provides reliability and safety, especially in areas where sometimes volatile chemicals and dyes are present.
Compressed air drives the spinning machines used in making yarn.
Powering Equipment
Compressed air drives air jet looms, spinning machines, ginning mills and other industrial equipment used to process denim, polyester yarns and other fabrics.
Air jet looms and many other pieces of equipment employ compressed air in the textile industry.
It also drives pneumatic components systems, controls the tension of the yarn in the spinning process, blows the yarn and removes dust.
Pneumatic systems control the tension of the yarn in the spinning process.
Support Specialized Processes
Air compressors provide air for dyeing machines, dryers and other finishing equipment. That air adds texture to fabrics and other details that increase the value of the finished product.
In the dyeing process, compressed air stirs dyeing agents and dries dyed products. It also controls the head and nozzle in the printing machine, helping execute precise designs, patterns and colors.
Compressed air controls the head and nozzle in a printing machine, helping to execute precise designs, patterns and colors on fabrics.
Conveying and Transporting
Pneumatic conveying systems transport textiles from one process to another. They also lift and handle heavy textiles.
Wastewater Treatment
Compressed air helps textile manufacturers move and dispose of waste products and chemicals generated during production.
Cleaning
Textile production generates large amounts of debris and dust. Compressed air helps keep facilities clean and equipment working well.
The Best Air Compressor for Textile Operations
There are many different kinds of compressors, but textile facilities usually either centrifugal or rotary screw compressors. Each offers some unique benefits, depending on the application:
-
- Centrifugal air compressors. Centrifugal compressors, also called dynamic compressors, create compressed air by increasing the air’s velocity using an impeller then slowing it with a diffuser. Extremely efficient, especially at high volumes, centrifugal compressors can produce a lot of air from a small footprint and are very durable. Unfortunately, they are less cost effective at lower sizes (typically less than 600HP) and are engineered for a specific pressure and flow.
- Rotary screw compressors. Rotary screw compressors have two rotors that rotate through a compression chamber and pressurize the air until it reaches the desired pressure. They range in size, typically up to 600 HP. Because they have fewer moving parts, rotary screw compressors are more reliable than other types of compressors. They can handle a 100% duty cycle—we recommend setting up your compressed air system so that they operate as close to full load as possible. In addition, they are very energy efficient and good at variations in demand. Best of all, they deliver high-quality air, meeting the needs of a wide variety of applications.
Generally, a centrifugal air compressor is most cost-effective for high-volume applications (above 2,500 CFM) common in many larger applications, but rotary screw air compressors are better for lower volumes. For more on the different types of compressors, read our blog post, “Which Type of Air Compressor Is Best for Your Application?”
Advantages of Rotary Screw Air Compressors
In our experience, rotary screw air compressors and are the best choice for most textile applications. They offer a wide range of advantages, including the following:
-
- Efficiency. Rotary screw air compressors are based on a simple, time-tested design that enables impressive efficiency. They deliver a continuous flow of air, resulting in smoother operation and significantly reduced energy waste. They operate continuously, minimizing fluctuations and enhancing overall efficiency.
- Safety. Compressed air systems are a natural for the industry because they are relatively safe, an important concern in any environment.
- Steady air flow. Rotary screw machines are known for producing steady streams of compressed air without the pulsations that sometimes occur with other types of compressors, especially reciprocating or piston compressors.
- Versatile. Rotary screw compressors work best with a 100% duty cycle—we recommend setting up your compressed air system so that they operate as close to full load as possible. In addition, they can handle variations in demand and temperature extremes.
- Less maintenance. Because they have fewer moving parts, rotary screw air compressors require less maintenance.
- Long-term reliability. Rotary screw machines are designed for long-term reliability, giving them a relatively low total cost of ownership.
- Footprint. Rotary screw air compressors are compact and occupy relatively little floor space.
- Quieter. Compared to other types of compressors (especially reciprocating machines), rotary screw air compressors make much less noise.
- Warranties. Rotary screw air compressors generally have better warranties than other types of air compressors because of their reliability, efficiency and long life. In fact, Kaishan’s KRSP and KRSP2 rotary screw compressors are backed by a lifetime warranty on the airend.
Kaishan’s KRSP and KRSP2 rotary screw compressors are backed by an unmatched lifetime airend warranty, thanks to their reliability, efficiency and long life.
Kaishan has several different models used in textile operations, including our KRSB belt-drive, KRSD direct-drive, KRSP premium single-stage and our KRSP2 premium two-stage air compressors.
Kaishan oversizes the coolers in its units, enabling them to handle the heat and humidity you’ll often find in an industrial-level textile operation. We design most units to withstand temperatures as high as 122°F, while many of our competitors list 104° to 115°F as their maximum temperatures.
Because of their reliability, efficiency and long life, Kaishan’s KRSP2 two-stage rotary screw air compressors are an excellent choice for textile manufacturers.
To prevent damage to end products, some textile companies use oil-free compressors to limit the chance of contamination. Kaishan’s new oil-free compressor, the KROF, sets new standards for reliability, efficiency and warranty protection, producing ISO 8573-1, Class 0 oil-free compressed air. It is available in 100-, 125- and 150-psig models with integrated air or water cooling. The KROF has a host of robust features that make it the best choice for demanding oil-free applications, including oversized stainless-steel precoolers on each stage that lower temperatures for both intercoolers and aftercoolers. Plus, the KROF is backed by an industry-leading five-year warranty on major components, including the airend.
Local Help
Need assistance selecting the right air compressor for your textile application? Kaishan can help. We work with a nationwide network of independent distributors, who can provide on-site help and consultation. Their people are factory-trained air compressor experts who can recommend the right equipment for your operation. And service your air compressor without a problem.
Key Takeaways
-
- Compressed air is critical to the textile industry, powering air jet looms, spinning machines, ginning mills and more.
- Because of their reliability, efficiency and long life, most air compressors used in the textile industry are either centrifugal or rotary screw air compressors.
- A centrifugal air compressor is most cost-effective for high-volume applications (above 2,500 CFM).
- Rotary screw air compressors are better for lower volumes.
Let Us Help
Designing an air compressor system for your textile manufacturing is critical to your success. If you need help choosing the right compressor, get in touch with the experts at Kaishan. Contact us today.
