Category Archives: Dental Compressor

Dental Compressor

How to Maintain the Dental Air Compressor

A dental air compressor pressurizes atmospheric air for use in procedures. Standard compressors are not suitable for this purpose because they may not meet health and safety standards. Dental firms can choose from an array of models designed for small, medium, and large practices with a variety of features.

The operation of an air system requires more than just an ability to turn the right switches. One of the most important aspects of the whole operation is the maintenance of the compressor and various other components, because this ensures long life and efficiency for an air system. Unfortunately, compressed air maintenance mistakes are often made by operators who’ve only familiarized themselves with the basic workings of the equipment.

Common mistakes in compressed air maintenance include failure to assess energy costs and the impacts of contamination and condensation. These mistakes alone can lead to inefficiency and parts failure that can result in losses in the tens of thousands over the course of a given year. Further compressed air maintenance mistakes include a lack of attention to secondary components and a failure to properly train all members on staff of the finer nuances of compressor operation.

Compressed air should always be oil free. Nonetheless, oil serves as a necessary evil in the process of air compression. As such, the process has its share of potential consequences. As the air is compressed, oil is used for the purposes of cooling, lubrication, and sealing. Unfortunately, up to half of the degraded oil can pass through the system in vaporized form, especially when temperatures are high. The system itself can also draw unburned hydrocarbons, which condense once cooled. When acidic oil vapors mesh with moisture in the compressed air, corrosive buildup forms along the air receivers and valve cylinders.

It must be noted that dental oilless air compressors are not contaminant-resistant compressors. In other words, the inlet valve of an oil-free compressor cannot magically filter out airborne contaminants from ambient air. Just as with an oil-lubricated system, an oil-free compressor needs filtration to keep water, dirt, unburned hydrocarbons, and other impurities from the compression process.

Some manufacturers offer refurbished units which have been carefully serviced before sale. These units are similar to those that are new, but have a lower price because they’ve been gently used. It may also be possible to rent a unit, which can help defray the startup costs for a dental practice. The equipment needed to start offering services to patients can be substantial, making it expensive to start a new business.

Dental Compressor

The Costs of Compressed Air Energy

The operation of an air system requires more than just an ability to turn the right switches. One of the most important aspects of the whole operation is the maintenance of the compressor and various other components, because this ensures long life and efficiency for an air system.

One of the biggest compressed air maintenance mistakes is to underestimate or miscalculate the amount of energy that a compressor will use within the span of a year. Fact is, the price to operate a dental air compressor can equal or exceed the purchasing cost of the machine in the space of just 12 months. Most problematic in this regard is the wasteful usage of a compressed air system, which often occurs when operators are unaware of the overall energy costs.

On average, an industrial air compressor will retail in the ballpark of $30,000 to $50,000. When you multiply the operating costs per hour by the number of usage hours per day across 12 months, the cost of operating the machine during the first year alone could well exceed the initial price, and that doesn’t even count any possible maintenance costs.

A reliable way to estimate annual energy costs is to take the compressor’s horsepower and multiply that by .746, then multiply that by the number of usage hours, then multiply that by the power rate, and finally divide the total by the motor efficiency.

To best assure efficiency, it’s important to accurately calculate the annual energy costs of an air compressor, and to make sure that all operating staff understand how the figure plays out on a daily basis. That way, wasteful system use can be curbed going forward.

Even though the compressor is the main component of concern within an air system, it’s not the only one in need of routine maintenance. Of equal importance during any maintenance inspection are the other components that facilitate the air supply. Chief among such components is the air receiver, which holds compressed air for times when air demands increase, and also reduces system wear and contamination.

The air receiver makes it possible to run the compressor at lower levels and conserve energy in the process. However, the air receiver won’t be able to do its job properly if it’s too small for the system, because the compressor will have to run longer than necessary to keep up with air demand. Therefore, it’s important to ensure that the air receiver is either large enough for the system, or backed with secondary receivers.

Dental Compressor

What Should You Know about the Dental Air Compressor

Safety should always be your first priority when working with compressed air, no matter the setting. It may seem like a simple tool and you might be tempted to blast a coworker with a burst of air, or use the compressed air to blow dirt or dust away from your skin, but this is dangerous behavior.

Compressed air is under such pressure that even brief contact with protected skin can cause abrasions, cuts and other injuries. If the skin is broken, an air compressor can force air under the skin, causing organ damage or even potentially causing an embolism — an air bubble in the blood that can cause a cardiac event if it reaches the heart. In rare cases, impacts from compressed air have been known to cause traumatic organ damage.

An air compressor could have perfectly functioning filtration and be free of condensate or traveling oil, yet still lag in its performance if air leaks are present at any point between the machine itself and the tools at the end of the pipes.

When air leaks form along a compressed air system, tool performance weakens and operations become less efficient. If an operator is unaware of the problem source, the first solution that often comes to mind is to simply crank up the pressure on the system in order to compensate for the lagging power. This, in turn, leads to increased wear and tear on the internal mechanisms of an air compressor.

Simply put, there’s nothing to be gained from leaks in a compressed air system. The problems associated with leaks are easier to spot and remedy, or prevent altogether, with routine inspections along all the parts that transport air from the compressor to the end tools.

Compressors need lubrication to function, but the oil can get into the airstream, where it could threaten patient health and jeopardize procedures. Some units are oil-free, while others have special sealant systems to prevent leaks. The dental air compressor may also be designed to operate quietly, which can reduce stress for patients who may be worried by the sound of a large engine running near the procedure room.

Buying a name-brand compressor can help reduce that risk even further by giving you access to approved service providers who are trained to maintain your specific piece of equipment. While using a different service provider for your dental equipment maintenance is one option, you aren’t guaranteed to be paired with a technician who knows all the ins and outs of your compressor’s idiosyncrasies.

Dental Compressor

The Problems of Dental Air Compressor

One major problem that emerges in compressed air systems is pressure drop, which is marked by a loss of pressure between the compressor and the end point. While a certain amount of pressure drop is inevitable, it should never amount to more than a 10 percent loss of pressure during a given application. Otherwise, higher pressure demands end up being placed on the compressor, which results in more rapid wear and tear across the entirety of an air system.

For each pound of pressure either increased or decreased, a power plus or minus 0.5 percent is required. For example, a five percent power savings can be gained with a decrease of 10 psig. On a 100 hp compressor, this would translate to $1,740 in annual energy savings.

Pressure drop is usually caused by trouble with the pipes and weaknesses at the filters and dryers. Unfortunately, system operators will often compensate for the pressure loss by boosting the system pressure, which results in costlier operations. The correct way to handle this issue is to check for problems at the filters and dryers and replace certain items as necessary.

It’s crucial for air system pipes to remain clean and free of dirt, rust or other contaminants. After all, compressed air reaches its end point through these pipes. When contaminants are present, air pressure weakens, and the problem gradually accelerates when left un–rectified. The pipes should always remove air from the top of the air line, otherwise contaminants will travel to the pneumatic tools.

Airstream contamination increases with velocity, which in turn increases with restrictions in pipe size. Basically, the velocity of the pipes that run to the end point should be 50 seconds or less, while the interconnecting pipes and main headers should have velocity in the range of 20 to 30 feet per second. System velocity can be calculated by dividing the flow in cfm by the pipe’s compression ratio, divided by the pipe area, divided by 60.

Another factor that can impact condensation is the ambient temperature that surrounds a facility. Simply put, condensation levels multiply as temperatures rise from average to humid. For example, a 200 hp compressor will produce roughly 50 gallons of condensate over the course of a 60–degree day. However, that same machine will generate more than five times the amount of condensate if the temperature is 30 degrees higher. A 200 hp compressor will produce roughly 50 gallons of condensate over the course of a 60-degree day.

Further inefficiency can stem from problems with the system drains, which are designed to deal with condensation. Drains are placed at strategic points along a dental air compressor system, such as the tank, dryer and aftercooler. The trouble emerges when the drain fails to do its job properly, and sludge accumulates along the drainage points from a mix of water, oil and dirt.

Some of the most common mistakes in compressed air maintenance are easily avoidable if everyone on an air system staff understands how to properly care for the equipment at hand. From the compressor itself to the various parts that make up an air system, routine inspections along key areas must be made for signs of wear, condensation and dirt deposits.

Dental Compressor

Common Mistakes in Air Compressor Maintenance

Common mistakes in compressed air maintenance include failure to assess energy costs and the impacts of contamination and condensation. These mistakes alone can lead to inefficiency and parts failure that can result in losses in the tens of thousands over the course of a given year. Further compressed air maintenance mistakes include a lack of attention to secondary components and a failure to properly train all members on staff of the finer nuances of compressor operation.

One of the biggest compressed air maintenance mistakes is to underestimate or miscalculate the amount of energy that a compressor will use within the span of a year. Fact is, the price to operate an air compressor can equal or exceed the purchasing cost of the machine in the space of just 12 months. Most problematic in this regard is the wasteful usage of a compressed air system, which often occurs when operators are unaware of the overall energy costs.

On average, an industrial air compressor will retail in the ballpark of $30,000 to $50,000. When you multiply the operating costs per hour by the number of usage hours per day across 12 months, the cost of operating the machine during the first year alone could well exceed the initial price, and that doesn’t even count any possible maintenance costs.

A reliable way to estimate annual energy costs is to take the compressor’s horsepower and multiply that by .746, then multiply that by the number of usage hours, then multiply that by the power rate, and finally divide the total by the motor efficiency.

To best assure efficiency, it’s important to accurately calculate the annual energy costs of an air compressor, and to make sure that all operating staff understand how the figure plays out on a daily basis. That way, wasteful system use can be curbed going forward.

Among certain air system operators, it’s simply assumed that maintenance begins and ends with a check of the compressor for signs of condensation and dirt. For operators who overlook the broader maintenance steps, the consequences can be confusing. After all, you can have a set of oilless air compressors that function perfectly, yet still have problems with the overall system.

Even though the compressor is the main component of concern within an air system, it’s not the only one in need of routine maintenance. Of equal importance during any maintenance inspection are the other components that facilitate the air supply. Chief among such components is the air receiver, which holds compressed air for times when air demands increase, and also reduces system wear and contamination.

The air receiver makes it possible to run the compressor at lower levels and conserve energy in the process. However, the air receiver won’t be able to do its job properly if it’s too small for the system, because the compressor will have to run longer than necessary to keep up with air demand. Therefore, it’s important to ensure that the air receiver is either large enough for the system, or backed with secondary receivers.

Dental Compressor

How to Choose the Good Dental Compressor

Some units are portable, allowing practitioners to move them around as needed. Others are mounted in a practice. For hygiene reasons, the dental air compressor is typically attached to short tubing. Dentists may place a unit between two treatment rooms, for example, providing access from either side while leaving the tubes short to reduce the risk of breeding bacteria. The best option for a facility can depend on the number of patients it sees and the kinds of procedures it performs with the use of compressed air.

A small compressor has the advantage of being lightweight, quieter and cheaper. However, if asked to work beyond its capacity, it will overheat and cut out. It is often suggested that if the practice intends to perform restorative work it is best to have an oilless compressor, to prevent oil droplets in the airline contaminating the restorative material.

The temperature that surrounds an air compressor is integral to the quality of the machine’s performance. If the air that surrounds the compressor is hotter than normal due to rising outdoor temperatures, it can affect the performance of pneumatic tools and machines. Therefore, it’s crucial to ensure that the air compressor itself maintains consistent temperatures throughout the year, including those months where outdoor temperatures top 80 degrees.

In recent years, increased awareness over the detriments of air contamination has spurred the development of advanced filtering systems for compressed air. The trend has gained steam in tandem with the move towards conservation and energy efficiency, both of which have been aided by the widespread adoption of pneumatic tools and machinery.

In order to prevent an air compressor from getting hotter during summer, the coolers must be cleaned each year just as temperatures begin to rise. If the coolers are clogged, it could impede their ability to keep your compressed air system at desired levels. To prevent this from happening, perform the following actions several weeks in advance of each summer:

Inspect the coolers for traces of dirt, gunk or misty residue.
Clean away any dirt deposits present on the coolers.

If the air compressor gets overheated, the impact could be troublesome for the compressor itself, as well as for any attached pneumatic tools and machinery. If a compressor is used to power air blowers, for example, the quality of air that reaches the end point could be ill–suited to the task at hand when the system is overheated.

Both new and used dental air compressor options are available. Some manufacturers offer refurbished units which have been carefully serviced before sale. These units are similar to those that are new, but have a lower price because they’ve been gently used. It may also be possible to rent a unit, which can help defray the startup costs for a dental practice. The equipment needed to start offering services to patients can be substantial, making it expensive to start a new business.

Dental Compressor

How to Save Energy of the Air Compressor

Studies have concluded that industrial plants waste roughly 30 percent of generated compressed air, which could equate to $9,600 for a typical scfm installation, or as much as $32,100 for 1,500 CFM. Estimates also indicate that poorly designed compressed air systems in the U.S. result in wasted utility payments of up to $3.2 billion.

Energy efficient air compressors will not only save money but will also help control pollution. A walk-through assessment can help identify conservation opportunities in your compressed air system.

Large-scale air emissions are released when electricity is produced. Reducing the electricity needed for compressed air systems can help significantly improve air quality.

Many industrial compressors use oil for lubrication, creating an oil and water mixture called condensate, which contains hydrocarbons and other harmful contaminants that require proper disposal in accordance with government guidelines. Oil water separators, used in condensate management systems, can help efficiently remove waste. An outside waste management company can help dispose of compressor condensate( oilless air compressor ).

Due to problems with piston rings on reciprocating compressors and premature modulation on rotary screw compressors, many compressors don’t produce the CFM flow for which they’ve been rated. Failure in this area may be the result of an inaccurately adjusted valve. Calibration can help verify compressor output.

Air compression equipment should maintain low pressure drop for the duration of its service life. Total pressure drops across system components shouldn’t exceed 15 psi. If pressure loss in your system is more than 10 percent, you should evaluate the distribution system and identify the causes of excessive pressure drops.

Air distribution piping should be large enough in size to minimize this pressure drop. Installing a pressure regulator can limit air demand while reducing maintenance costs and extending tool life. Inlet air filters can prevent the kind of dirt that restricts airflow and causes pressure drops.

You can experience cost savings from using an efficient air compressor. But compressed air can be one of the most expensive forms of energy in a manufacturing plant, with eight horsepower of electricity generating one horsepower of compressed air. In fact, the annual cost of electrical power can often exceed the initial cost of the air compressor.

Dental Compressor

Paying Attention on Maintaining the Air Compressor

Maintenance of an air compressor unit is only part of what keeps a compressed air system in optimal condition throughout the four seasons of a given year. In order to keep a well–functioning compressor performing up to par, you also need to ensure that the compressor room is maintained with optimal working conditions for the machinery contained within.

As with the air and oil filters within the dental air compressor, it’s important to check the ventilation for the room that houses the machine. To prevent the ambient air from becoming too congested, perform the following steps on a routine basis:

Check air vents for dust deposits.
Clear away dust buildup from air vents.
Inspect the HVAC system for dust buildup and defects.

In any kind of work environment, the air needs to circulate in order to remain healthy. Even if you have an HVAC system in place that’s been especially programmed to maintain suitable temperatures and ambient air quality inside the room that stores your compressed air system, the HVAC unit itself could become compromised if not subject to periodic inspections. This, in turn, could degrade the quality of air within the compressor room and have a domino effect on the compressor and related tools. All such problems can be prevented with routine inspections of the air vents and HVAC system.

When water is the cooling factor in any kind of air system, the water itself must be cool in order for it to have the desired effect. When the weather gets warmer, the water that goes in should be even cooler. Just as with air coolers, a water–cooled air compressor needs sufficiently cool water to offset the ambient warmth during hotter months.

To ensure that the water in a water–cooled air compressor maintains sufficient coolness, perform the following actions before each working cycle that takes place during humid days:

Check the temperature of the water.
Adjust the water temperature if necessary when ambient temperatures rise.

With any machine that has been made to supply quality air, external factors can impact the performance of the machine and the quality of air that reaches the end point. In the case of a water–cooled air compressor, the quality of compressed air is liable to be compromised if a normally cold water supply is rendered warmer by humid ambient temperatures. To prevent such problems from occurring, check the water supply during hotter months to ensure that the water temperature remains consistent with fall, winter and spring levels.

Dental Compressor

The Importance of Maintaining the Dental Air Compressor

The cleaner the air your compressor creates and uses, the safer your patients. In a dental practice, there is the risk of exposure to bacteria, microorganisms and pathogens. When equipment is producing poor-quality air, or it’s improperly generating a moist environment in machine parts, you could be creating a breeding ground for these dangers.

The filtration system is integral to the efficiency of an air compressor. As long as the air and oil are sufficiently filtered throughout a given cycle, the dental air compressor can be expected to produce cool air at consistent volumes with an overall smooth performance from the machine. However, if the filters are clogged with dirt, pressure drop can ensue, and this forces the air compressor to work harder just to perform basic functions. Consequently, energy gets consumed and parts get worn in the process.

If gunk and dirt are allowed to accumulate over several seasons, the decline in air quality could serve as a warning sign of costlier problems down the way with an air compressor. To prevent these problems from occurring in the first place, check the filters regularly and clean them out as needed.

Maintenance of an air compressor unit is only part of what keeps a compressed air system in optimal condition throughout the four seasons of a given year. In order to keep a well–functioning compressor performing up to par, you also need to ensure that the compressor room is maintained with optimal working conditions for the machinery contained within.

As with the air and oil filters within the air compressor, it’s important to check the ventilation for the room that houses the machine. To prevent the ambient air from becoming too congested, perform the following steps on a routine basis:

Check air vents for dust deposits.
Clear away dust buildup from air vents.
Inspect the HVAC system for dust buildup and defects.

In any kind of work environment, the air needs to circulate in order to remain healthy. Even if you have an HVAC system in place that’s been especially programmed to maintain suitable temperatures and ambient air quality inside the room that stores your compressed air system, the HVAC unit itself could become compromised if not subject to periodic inspections.

An air compressor is capable of working under all types of weather, providing that the compressor is kept in optimal shape and the operating environment is suited to the technology. With periodic maintenance of your compressed air system and its room of operation, you could enjoy optimal performance throughout the year with minimal downtime.

Dental Compressor

The Improve of Dental Vacuum Systems

Whenever operating a dental air compressor or any other noisy equipment — lawnmowers, food blenders, vacuums, etc. — it’s wise to wear earplugs to protect your hearing. Even though you might feel as though your ears are tough enough to bear the volume, ears are like eyes. In the same way that vision diminishes somewhat over the course of life, so too does hearing. As with eyesight, the weakening of the ear drum can be accelerated through constant abuse.

The dentist with a wet vacuum system is hit with a double water bill, once on the way in, and again on the way out. Since, a dry vacuum system does not require the water that wet systems do, there is a very positive financial impact (in addition to the environmental one) in switching to the newer technology when the old system needs to be replaced.

The recent introduction of various dry vacuum systems eliminates these concerns and provides excellent clinical vacuuming power. The concerns of retro-fitting a new unit center on practicality and cost. The replacement dry system should be no larger than the existing wet one, and should preferably provide more suction capacity for the practice. Other parameters include reduction of noise and the drainage requirements; most wet system traps must be drained on a regular basis, a task usually allotted (due to its popularity) to the staff member with the least seniority.

Both systems work well for dentistry. However, a new wet vac creates up to 15″ Hg suction pressure while a new dry vac (some but not all) creates up to 25″ Hg. This provides the power and performance that the dentist expects from the vacuum system. This is probably the single most important factor to consider when selecting a new vacuum and should be carefully researched. (Some dry vacs produce only 8″ Hg suction pressure.)

Many of the currently available dry vacs utilize oil in their motors( micro motor ) for lubrication and cooling, much like a car. The “oil” dry vacs therefore exhaust oil vapors which pollute their immediate environment. The also require regular oil maintenance. The newer dental dry vacs can create powerful vacuum without using oil. Carbon fiber vanes eliminate the need for oil in the process. There are no oil levels to check, no oil to add, no oil to change, and most importantly, no oil in the exhaust that can be harmful to people and animals, and can cause severe damage to a roof or building exterior.

Some “dry” vacuum systems offer a unique air-water separator. There is a compact plastic air-water separator that collects liquids and drains them efficiently into a small 20 gallon pail. Working with a gravity drain design, the tank drains every time the pump is shut off. The smaller tank drains more frequently, reducing the odors that are often synonymous with dental evacuation systems. This also eliminates the need for cleaning (something that every staff member will appreciate). Should the tank require draining during the day, the cycle takes approximately 6 minutes.