The number of craft breweries in the U.S. has increased six-fold in 15 years, spurring the brewing industry at large to significant growth.
In fact, the Brewers Association placed the number of craft breweries at 9,247 in 2022, including 1,886 microbreweries, 3,307 brewpubs, 3,702 taproom breweries and 223 regional craft breweries.
This group, the trade organization representing small and independent American craft brewers, estimated retail sales of beer reached $27.9 billion in 2021, a 21% jump over pandemic-impacted 2020, as consumers returned to what the association calls “on-premises” consumption. Or in other words, consumers returned to the bars.
That growth has not gone unnoticed in the compressed air industry, which plays an essential role in brewing. We can all raise our glasses on that point.
Breweries Turn to Compressed Air
Compressed air is used in a wide range of applications in a typical brewery operation because of its versatility, cleanliness and flexibility.
Air compressors power equipment from large machines to hand-held power tools and precision pneumatics. Compressed air is also cleaner and safer than other potential power sources, a key consideration for breweries hoping to differentiate their products on quality, clarity and taste.
Plus, its ability to be stored and used on demand gives compressed air admirable flexibility across a brewery of any size.
Range of Applications
Air compressors are used in a wide range of applications in a typical brewery operation:
Moving/Transferring Beer
Compressed air helps move beer from the brewing or conditioning tank to bottling or canning. Compressed air is the most efficient way to ensure the lines stay clean and dry between different parts of the process.
Aeration
During the fermentation process, air compressors deliver oxygen the yeast needs to convert sugars to alcohol. Compressed air is the best way to do that in a controlled, efficient and clean manner.
Clarification
Air compressors drive centrifuges that remove solid material from the beer, giving it that clear appearance and clean taste beer drinkers love.
Cleaning
Brewers use compressed air to clean all kinds of equipment, including kettles, tanks, kegs and bottles, to keep their operation clean and free of contaminants. The stakes are high: impurities can alter the taste of the beer and even force the brewer to discard entire batches of product.
Packaging
Compressed air drives critical machinery in the packaging area, especially equipment that labels cans or bottles. It also powers the valves that control the flow of beer during packaging.
Pneumatic Tools
Brewers use pneumatic tools, including drills, grinders and saws, to cut and shape materials or create custom components. All are powered by compressed air.
Cooling and Refrigeration
Compressed air powers compressors and fans that run the cooling and refrigeration units that keep the beer at a constant temperature.
Rotary Screw Compressors
Rotary screw models are the compressors of choice in the brewing industry because of their rugged reliability, energy efficiency, continuous duty, airflow consistency and quiet operation.
Oil-free vs. Oil-lubricated
Advocates often pressure brewing companies to use oil-free compressors, raising the possibility of oil contamination. They claim that oil-free models provide better air quality and don’t need the air purification equipment installed in oil-lubricated compressors.
There is no question that brewers should use oil-free compressors to service applications like moving beer from the brewing or conditioning tank. Or the aeration step, where the compressed air will touch the product.
But there are some significant downsides to use of oil-free compressors:
- There’s still oil. Oil-free doesn’t mean there’s no oil. Hydrocarbon vapor from car exhaust and industrial processes still is present in the ambient air and can cool and condense when drawn into a compressor, causing problems in your system. So, it still must be removed.
- You still need filters. While oil-free machines do not introduce oil, they still use atmospheric air, which contains water vapor, dirt, microorganisms, rust and pipe scale, among other things. As a result, you still need filters to remove them.
- Temperature. Because they lack the cooling capability oil provides in oil-lubricated machines, oil-free compressors produce air that is hot and moisture-laden. The air must be treated before it can be distributed through your compressed air system.
- Energy use. Oil free compressors are less efficient than oil flooded compressors, adding to the operating costs. The added lubrication allows for closer tolerances in the airend and housing, giving oil-lubricated compressors more CFM/HP. That improved performance cuts electrical cost by about 5%.
- Initial cost. New oil-free compressors cost $400-500 per horsepower, significantly more than oil-lubricated compressors at $250-300/hp.
- Maintenance. Oil-free compressors require expensive overhauls or airend replacements every few years, while oil-lubricated models only need an oil change and replacement of the air-oil separator annually.
- Warranties. Because of their greater reliability, manufacturers offer attractive warranties on oil-lubricated equipment. Kaishan offers a five-year warranty on major components and a lifetime warranty on the airend on our KRSP and KRSP2 premium rotary screw air compressors. Warranties on oil-free equipment vary by manufacturer between one and four years on the airend and one year on the rest of the package.
- Total cost of ownership. Perhaps the primary factor. When you add the acquisition cost, the increased energy cost and the need for expensive maintenance, air cooling and treatment make oil-lubricated compressors much more cost-effective.
Kaishan always recommends oil-free compressors for those applications where the air comes in direct contact with the product, like the moving/transferring steps. However, we make sure our customers recognize and are prepared for the drawbacks of oil-free machines.
And we encourage them to explore the use oil-lubricated compressors for all non-contact applications.
Most Brewers Go with Oil-Lubricated Compressors
Because of the limitations of oil-free machines, most breweries rely on oil-lubricated rotary screw compressors and food grade oil for applications where the air does not come in direct contact with the product.
Kaishan has several different models that are used in breweries, including our KRSB belt-drive and KRSD single-stage air compressors. We also offer Kaishan industrial vacuum pumps that reduce energy use and lower operating cost.
Stainless Steel Tubing
Kaishan is one of the few manufacturers that use stainless-steel control tubing in all their compressors. The 316 stainless steel we use contains molybdenum, which gives our tubing greater strength, hardness, electrical conductivity and resistance to corrosion and wear, when compared to regular 304 stainless. It’s yet another way we help provide the high-quality compressed air the brewery industry needs.
See Kaishan Compressors in Action!
Kaishan’s stainless steel tubing, oversized oil and air coolers and automatic belt tensioning on the KRSB belt-drive compressors helped Life Is Brewing achieve the reliability and efficiency they were seeking. Read the Life Is Brewing case study.
Consulting Help
Kaishan is fortunate to work with a nationwide network of independent distributors, who have the skills and experience to provide on-site help and consultation as needed. These factory-trained air compression experts have an investment in their local communities and help you develop and operate an air compressor system that meets your needs.
Key Takeaways
- Wide-ranging. Industrial air compressors are used in a variety of applications in breweries, including moving/transferring beer, aeration, clarification, cleaning, packaging, powering pneumatic tools and cooling and refrigeration.
- Oil-free vs. oil-lubricated. While some advocate using oil-free compressors and food grade oil, oil-lubricated compressors offer many advantages, including lower initial cost, better warranties, lower energy use and less expensive maintenance.
- Oil-free is used sparingly. Because of the increased costs, breweries typically only use oil-free compressors where absolutely required. In effect, where the compressed air comes in contact with the product.
Let Us Help
Finding the right air compressor system is critical for your brewery’s success. The right compressor can save you time and money and ensure your compressed air system operates correctly. If you need help finding a qualified professional to evaluate your needs and find the right compressor for your brewery, get in touch with the experts at Kaishan. Contact us today.