FOOD & BEVERAGE
ELGi navigates the water-injected technology choices available for critical applications that require oil-free compressed air
il-free compressed air has become a quintessential requirement in the modern manufacturing space. The increasing environmental concerns and the emphasis on energy conservation and sustainability propel this growth. As environmental regulations tighten and industries push for cleaner, safer processes, the global Oil-Free Air Compressor Market continues to expand - valued at 17.34 billion Euros in 2023 and projected to reach 30.52 billion Euros by 2030, growing at a CAGR of 7.5% during the forecast period (2023–2030). This demand for oil-free compressed air continues to accelerate, particularly across industries where contamination risks cannot be tolerated.
Pharmaceutical manufacturing, food and beverage processing, electronics production, and other sensitive applications require ISO 8573-1 Class ‘0’ oil-free compressed air — a standard that reduces the possibility of oil contamination. The technology choices for achieving truly oil-free compressed air have evolved significantly, with water-injected screw compressors emerging as a compelling alternative to traditional oil-free solutions.
The challenge facing industry professionals is not simply achieving oil-free compressed air, but doing so in a way that balances performance, reliability, and total cost of ownership. This balance becomes critical when evaluating water-injected technologies, where design differences between manufacturers can significantly impact operational success and satisfaction. Modern industrial applications demand oil- free compressed air for reasons that extend well beyond regulatory compliance. For example, in food and beverage processing, oil contamination puts product quality and brand reputation at risk.
The ISO 8573-1 Class ‘0’ standard represents the highest level of oil-free compressed air requirements. Achieving this standard requires purpose-built oil-free technology rather than attempting to filter oil from conventionally lubricated compressors. Whilst filtration systems can achieve Class 1 ratings, the physics of oil removal makes Class ‘0’ impossible through filtration alone. ISO 22000 food safety management standards further emphasise the importance
THE OIL-FREE REVOLUTION O
of contamination
prevention throughout the production process. For compressed air systems serving food processing applications, this means not only achieving oil-free
compressed air but maintaining that purity from the air compressor manufacturing process throughout the distribution system and storage components.
The market offers several approaches to oil- free compressed air generation, each with distinct advantages and limitations. Oil-lubricated compressors with extensive
filtration represent the most common but not- so-effective approach. Whilst this solution may appear cost-effective initially, the combination of energy losses through multiple filtration stages and the impossibility of achieving Class ‘0’ ratings makes this approach unsuitable for critical applications. The ongoing filter replacement costs and energy penalties associated with pressure drops across filtration systems create hidden costs that accumulate over the system lifecycle. Dry screw oil-free compressors offer proven performance for larger applications, typically ranging from 45kW to 450kW and beyond. These systems utilise specialised coatings and precise clearances to achieve compression without lubrication. However, they often have a higher purchase price and more demanding maintenance requirements. The technology works well for large installations. Dry tooth oil-free compressors provide another proven approach, utilising different rotor profiles optimised for oil-free operation. Whilst effective, these systems typically require two-stage compression and involve higher maintenance costs.
Water-injected screw compressors represent a newer approach that addresses many limitations of traditional oil-free technologies. By using water instead of oil for sealing and cooling, these systems achieve inherent oil-free compressed air operation whilst maintaining the reliability and efficiency characteristics of liquid-injected compression. Water-injected compressors offer several compelling advantages for oil-free compressed air applications. The inherent oil- free design provides complete peace of mind regarding contamination risks, eliminating the
30 JULY/AUGUST 2025 | PROCESS & CONTROL potential filter failures or
breakthrough contamination events. The technology requires fewer accessories compared to dry oil-free systems, reducing both initial costs and ongoing maintenance requirements.
Total cost of ownership often favours water- injected systems, particularly for smaller to medium compressed air requirements where dry oil-free systems may be oversized or economically impractical. The availability of water-injected technology in lower power ranges makes oil-free compressed air accessible for applications that previously relied on filtered oil-lubricated systems. However, successful implementation of water-injected technology requires careful consideration of design choices that significantly impact reliability and operational costs. The water management approach fundamentally determines the operational characteristics and reliability of water-injected compressors. Some manufacturers incorporate reverse osmosis systems to maintain water purity, believing this approach provides superior contamination control. However, the complexity of maintaining reverse osmosis systems often exceeds the maintenance requirements of the compressor itself, creating an operational burden that contradicts the simplicity advantages of water-injected technology. Alternative approaches to water management focus on preventing bacterial growth through elevated operating temperatures and proper system design. This approach, combined with ISO 8573-7 compliance for bacterial contamination prevention, can achieve superior reliability whilst eliminating the complexity and failure risks associated with reverse osmosis systems. The full feature can be read here:
https://processandcontrolmag.co.uk/oil- free-compressed-air-revolution/
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