Most companies set their own specific objectives and key performance indicators for compressed air use. And we’ve covered some of the obvious KPIs for the major benefits in several recently published blog posts, including:
However, some industries have unique needs specific to their segment. And, thus, they require metrics that monitor those needs. For more details on the ISO 8573-1:2010 requirements described below, download the Compressed Air & Gas Institute’s Compressed Air Purity Guide.
Let’s review some of those specialized industry measurements. We’ll start with electronics.
Air Compressor Measurement by Industry
| Industry | Compressed Air Uses | Key Air Issues |
|---|---|---|
| Electronics | Precision assembling, cleaning, testing | Cleanliness, low humidity, stable pressure |
| Food and beverage | Packaging, bottling, material handling | Compliance with FDA, USDA regulations, ISO 8573 |
| Healthcare | Powering surgical tools, respiratory support | Sterility, reliability, air quality |
| Semiconductor | Cleaning, handling and assembly, environmental control, etching and deposition, drying, cooling, wastewater treatment and nitrogen generation | Class 0 clean air, careful regulation of temperature, pressure, moisture level |
| Automotive | Metalworking, injection molding, material handling, finishing, assembly, robotics | Dirt, dust, heat |
| Cement plants | Pneumatic conveying, material handling, powering equipment | Dust, dirt, particulate matter, pressure stability |
| Steel mills, metalworking | Pneumatic tools, cooling systems, material handling | Temperature, oil and contaminant levels, VSD and VFD compatibility |
Compressed Air Metrics for the Electronics Industry
The electronics industry relies heavily on compressed air for manufacturing processes, including assembly, cleaning and component testing. The industry’s use of pick-and-place robotics, for instance, requires consistent pressure levels.
In addition, the requirements for compressed air in this industry are particularly stringent due to the sensitivity of electronic components.
Key Air Issues
- Purity. Contaminated air can damage sensitive components. Using air that meets specific cleanliness standards (like ISO 8573) is critical.
- Low humidity. Moisture can cause short circuits or corrosion, so maintaining low humidity levels is essential.
- Stable pressure. Fluctuating pressure can disrupt production processes, making it vital to maintain a consistent pressure level.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Oil content | Below 1 PPM |
| Moisture content | Below -40°F (-40°C) |
| Particle content | Less than 0.1 mg/m³ (100 PPM) |
| System pressure | Variations of less than 2 PSIG |
Compressed Air Metrics for the Food and Beverage Industry
Compressed Air Uses
Food processing plants use compressed air in many different applications, including packaging, bottling and material handling. These uses are often grouped by the level of contact the air will have with food products:
- Direct-contact applications involve situations in which air comes into direct contact with the food. Specific equipment includes all processing equipment, such as mixers and ovens, as well as some initial packaging equipment.
- Indirect contact uses occur in the latter stages of the food production process, after the product is initially packaged. Equipment includes form-fill-seal machines, cartoners and case packers, where a barrier, usually packaging material, separates the compressed air from the food.
- Ambient contact refers to the air inside the factory. But that doesn’t mean it’s harmless. The ambient air entering your compressor can contain millions of organic and inorganic particles, water vapor, atmospheric pollutants and diesel fumes. All those contaminants are concentrated during compression and can contaminate food products.
Key Air Issues
- Regulatory compliance. Your air must comply with FDA and USDA regulations as well as ISO 8573.
- Dry air: Moisture can promote bacterial growth, so air must be kept dry.
- Non-oily air: Oil contamination can ruin food products.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Oil content | Generally, below 0.1 PPM, but sometimes as low as 0.01 PPM |
| Moisture content | Below -50°F (-45°C) |
| Particle content | Less than 1 mg/m³ (1000 PPM) |
Compressed Air Metrics for the Healthcare Industry
Compressed Air Uses
Healthcare facilities depend on compressed air for various critical applications, from powering surgical tools to providing respiratory support. Since lives are at stake, precision and cleanliness are critical concerns.
Key Air Issues
- Sterility: Compressed air used in healthcare must be free of contaminants and meet strict sterility standards.
- Reliability: Systems must be reliable to support life-saving equipment without failure.
- Quality control: Air quality must be consistently monitored to ensure it meets regulatory standards.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Oil content | Below 0.1 PPM |
| Moisture content | Below -40°F (-40°C) |
| Particle content | Less than 0.1 mg/m³ (100 PPM) |
| System pressure | Variations of less than 2 PSIG |
Compressed Air Metrics for the Semiconductor Industry
Compressed Air Uses
Semiconductor fabricators use compressed air for precision cleaning, handling and assembly, environmental control, etching and deposition, drying, cooling, wastewater treatment and nitrogen generation.
Even the tiniest dust particles can ruin an entire wafer, so fabrication plants often turn to compressed air for clean, low-impact, non-abrasive cleaning. Pneumatic tools powered by compressed air enable the precise movement and placement of wafers and delicate components. Compressed air even helps deposit or remove materials in the thin, uniform layers a chip design requires.
Key Air Issues
- Ultra-clean air: Contaminants can ruin delicate semiconductor components, so air must be exceptionally clean. To achieve Class 0 compressed air, compressors require specialized filters to remove dust and other particles. They may even need pre-filters and after-filters.
- Controlled temperature and pressure: Fluctuations can affect product quality and yield rates.
- Moisture control: As in electronics, moisture can cause significant issues, so monitoring is essential.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Oil content | Generally, below 0.01 PPM |
| Moisture content | Below -70°F (-57°C) |
| Particle content | Less than 0.01 mg/m³ (10 PPM) |
| Other measurements | Temperature Microbial contamination levels Total hydrocarbons ISO 14644 cleanliness testing is sometimes necessary |
Compressed Air Metrics for the Automotive Industry
Compressed Air Uses
Automotive assemblers use compressed air throughout their plants:
- Metalworking equipment (plasma cutting and welding, forming equipment) and machine tools (computer numerical control/CNCs, lathes and milling machines) create everything from bumpers and mirrors to complex motor parts.
- Injection and blow molding shape plastic and composite materials, helping the industry meet the U.S. National Highway Traffic Safety Administration’s Corporate Average Fuel Economy (CAFE) standards.
- Pneumatics power the conveyors that help move and lift products and materials through the automotive assembly process. And pneumatic actuators control automated systems, machines and processes.
- Finishing processes, including painting, powder coating and electroplating, require a steady flow of compressed air without pulsations or uneven flows. The industry typically demands Class 1 or 2 air for oil and particulates to prevent finish defects and Class 2 or 3 for moisture to avoid corrosion and “fisheyes” in paint.
- Hand-held grinders, sanders, impact wrenches, drills and saws do the close assembly work that goes into a vehicle as it comes together.
- Robotics and automation equipment do the heavy lifting, hoisting engines, transmissions, quarter panels, door pillars, side panels and roof pieces and placing them on the chassis.
Key Air Issues
- Dirt and dust. Air entering a compressor is often dusty and dirty, loaded with conductive materials from welding and other processes.
- Heat. The temperatures characteristic of automotive environments (especially in metalworking areas) create special problems. And, because hot air is thinner, your compressor produces less air flow (CFM). All those things make your system—compressors, coolers and dryers—work harder.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Oil content | Below 0.01 PPM |
| Moisture content | Below -40°F (-40°C) |
| Particle content | Less than 0.1-0.5 mg/m³ (100 PPM) |
Compressed Air Metrics for Cement Plants
Compressed Air Uses
Cement plants operate in environments filled with dust and particulate matter. Compressed air is essential for processes such as pneumatic conveying, material handling and equipment operation.
Key Air Issues
- Dust control: Fine dust can contaminate the compressed air system and affect equipment performance. Monitoring dust and particulate levels in the air and regularly testing filter performance are essential to maintaining air quality.
- Durability: Equipment must withstand harsh conditions, including high levels of particulate matter.
- Pressure stability: Consistent pressure is crucial for the efficient operation of pneumatic systems.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Particle content | Less than 5 mg/m³ (5000 PPM) |
| Filter efficiency | Monitor your inlet air filter’s pressure differential (or ΔP, the difference between the incoming and outgoing pressures) and replace it if it’s more than 10 CFM. |
Compressed Air Metrics for Steel Mills and Metalworking
Compressed Air Uses
Steel mills require compressed air for various applications, including pneumatic tools, cooling systems and material handling. The environment can be hot and laden with particulates, which present unique challenges.
Compressors supply the large volumes of blast air steelmakers need to reach the required temperatures and drive combustion. It also helps regulate air pressure to ensure the flow of molten metal during smelting and casting, preventing the formation of bubbles and defects.
It drives the pneumatic devices that operate the rolling system’s hydraulics and power the controls, automation and testing equipment. It also drives air tools such as grinders, sanders, impact wrenches and drills, as well as pneumatic conveying systems that do much of the material handling.
In addition, compressed air supports the cooling system, ensuring that furnace temperatures are closely regulated. It prevents overheating and equipment damage, reducing the risk of fire and explosion, enhancing worker safety and extending the equipment’s service life.
Compressed air also enables air separation (including nitrogen and oxygen production), dust collection and cleaning.
Key Air Issues
- Temperature: Monitoring intake and discharge temperatures to prevent overheating.
- Oil and contaminant levels: Compressed air ensures that oil and particulates remain below acceptable thresholds to protect equipment and enable plants to produce steel with the precise balance of alloys and other chemicals that customers need.
- VSD and VFD compatibility: Variable speed drives (VSDs) and variable frequency drives (VFDs) need clean air to function optimally.
Compressed Air KPIs
| Metric | KPI |
|---|---|
| Particle content | Less than 5 mg/m³ (5000 PPM) |
Help in Measuring the Right Things
The choices you make about what to measure and how to measure it could well determine your company’s success in achieving broader objectives such as reliability, energy efficiency and cost efficiency. That’s why measurement is so important.
No matter what industry you’re in or what your management goals are, you can always benefit from expert help in deciding what KPIs you want to track in your compressed air system.
Find a compressed air professional near you. Or contact us directly.
Compressed Air KPIs
| Industry | Industry |
|---|---|
| Electronics | Oil content, moisture content, particle content, system pressure |
| Food and beverage | Oil content, moisture content, particle content |
| Healthcare | Oil content, moisture content, particle content |
| Semiconductor | Oil content, moisture content, particle content, temperature, microbial contamination levels, total hydrocarbons, ISO 14644 cleanliness testing |
| Automotive | Oil content, moisture content, particle content |
| Cement plants | Particle content, filter efficiency |
| Steel mills, metalworking | Particle content |
Need Help Setting the Right Metric?
Tracking the right compressed air measurements is critical to the operation of your system and to the processes that rely on it. We can help. Kaishan USA works with a nationwide network of independent distributors, who can provide on-site help and consultation as needed. Find the one closest to you. Or, feel free to contact us directly.