Best Commercial Air Compressors (Reviews and Buying Guide 2020)
Industrial air compressors are the most powerful category of compressors available in the market. Industrial air compressors are highly durable, designed to withstand the rigors of any job-site for long periods. They are used in everything from automotive body shops, construction sites, dental and medical clinics, workshops, auto repair shops, air conditioning, and ventilation systems to operating parts of an assembly line.
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Air Compressor Features
Power Source: air compressors are generally available in two modes, electric and gas. Air compressors that use electric motors are usually quieter, cheaper, and free of emissions. Most of the electronic air compressors are corded, however, some brands also offer battery-operated models (cordless).
Gas-powered air compressors are best suited for job sites that require extra power and have no immediate access to electricity. Gas compressors are heavier, require higher maintenance, and are usually noisier.
Air Volume: Air volume reflects the amount of volume of air generated by the air compressor into its tanks in a minute. Air volume is typically measured in cubic feet per minute (CFM), or standard CFM (SCFM) and is an essential factor in deciding the best compressor system.
If you use multiple tools simultaneously, then you will require an air compressor with a higher CFM rating. Most of the devices using the air compressor comes with the minimum CFM requirement. For example, an air caulking gun needs an air compressor with a capacity of at least 4 CFM. On the other hand, a more prominent tool such as a 3/4-inch impact wrench would require an air compressor that delivers around 14 CFM.
Pressure: This refers to the air pressure and force that the air compressor can deliver, and is measured in pounds per square inch (PSI). A higher PSI denotes that a larger volume of air that can be compressed in the tank. Generally, car tires require around 30 to 35 PSI, while air-powered tools need about 90 to 100 PSI to work. On the other hand, heavy-duty jobs such as operating lifts or running impact wrenches, need approximately 200 PSI.
Capacity: The size of the air compressor tank determines its operating time. Higher the capacity, the longer you can use your tools without waiting for the air compressor to raise the pressure to the appropriate level. For example, for smaller tasks such as inflating balls and tires, a 4 to 6-gallon tank would suffice, however, for power-consuming tasks such as a sander and airbrush, it will be ideal to have a higher capacity tank.
Motor Power: Motor power measures the power produced by the compressor’s motor. In smaller units, these are usually stated as horsepower (HP), while industrial units display output in terms of kilowatts (kW).
As per research, a piece of compressed air equipment cost more than eight times as compared to using an electrically driven device. Having a compressor that generates more power than your requirements will be expensive due to inflated capital, energy, maintenance, and repair expenses. Hence, you should only oversize your compressor if you foresee growth in your air requirements in the near future.
Voltage: Industrial air compressors come with two voltage options: 208-230V and 460V, so it’s crucial to install the compressor as per voltage. Sometimes, both the voltage options are available in the plant, then it is better to go for the higher voltage because energy consumptions remain the same regardless of voltage, but running a high voltage circuit is more cost-efficient.
Duty Cycle: Duty cycle denotes the percentage for the number of minutes the compressor can run in 10 minutes. For example, a compressor with a 50% duty cycle means that it should not be operated for more than 5 minutes out of any 10 minutes. Exceeding the duty cycle will put more pressure on the pump and will generate more heat, which may lead to quicker wear and tear and possibly a breakdown.
An air compressor with a 100% duty-cycle would be more efficient as compared to an air compressor, which generates more power but has a low duty cycle. For example, a 5 HP compressor with a 100% duty cycle will generate more air, as compared to a 7.5 HP compressor with a typical 75% duty cycle, as the air compressor with a 100% duty cycle allows it to be run continuously for extensive works.
Tank Size: Tank size determines the amount of air it can hold and is denoted in gallons. If you are going to use the air compressor for a small task or intermittently, then a small tank would suffice. However, if you want to operate a tool consistently for a long duration, such as a sander, then it would be better to go for larger tank size. While a small tank is portable and reaches the required pressure level quickly, a large tank wouldn’t run out of air fast, thereby enabling you to work consistently.
Type of Compressors: Direct-drive compressors are directly connected to the motor shaft and generate the same speed as the motor. Most of the standard direct drive compressors run at low RPM. If you require higher air volume and do not like to carry the compressor around, then belt-drive oil-lubricated compressors would be ideal, as the pump can spin at a slower rate compared to the motor, making it efficient and less suspect to wear and tear.
Best Industrial Air Compressors and Their Reviews
Campbell Hausfeld 80-gallon 2 Stage Air Compressor (XC802100)
The XC82100 80-gallon 2 Stage Air Compressor is manufactured by Campbell Hausfeld, an established name in the air compressor industry. The air compressor uses a 230V power supply and is designed to tackle a wide variety of jobs, from rotating wheels, paint spraying, sanding, grinding welds, and heavy-duty nailing and bolting projects.
The vertical air compressor features a 240 volt, 5 HP heavy-duty induction motor that creates maximum pressure to operate a broader range of tools while maintaining longer compressor run times. Made from high-quality materials, the XC802100 is highly durable and boasts an expected working time of 12,000 hours.
The XC802100 is capable of generating 175 PSI max pressure and 11.9 SCFM at 90 PSI. It can efficiently operate about 20 heavy-duty, high-demand tools such as air grinders and air sanders. The stationary air compressors’ quicker recovery time will enable you to spend more time on the projects instead of waiting for the compressor to increase the pressure at the appropriate level. The XC802100 is also equipped with a cooler, which reduces the chances of overheating.
The Campbell Hausfeld, electric air compressor features a cast iron, oil-lubricated 2 stage pump. The 80-gallon, Vertical ASME tank maximizes floor space, leaving a reduced product footprint.
Pros
Long-lasting with 12,000 hours of usage
Suitable for multi-tool operation
Space-saving design
Two-stage pump eliminates waiting time
Cons
Quite noisy
From running sanders to big blast cabinet, the Campbell Hausfeld XC802100 is capable of handling everything thrown at it effectively.
Quincy QT-54 Splash Lubricated Reciprocating Air Compressor
The gas-powered Quincy QT-54 Splash lubricated reciprocating air compressor is built for efficiency. The air compressor is equipped with an industrial-duty made in USA Baldor motor for durability and generates compressed air at a lower horsepower.
The Quincy QT-54 air compressor is capable of delivering a 145-175 working PSI at a 1310 pump RPM. The air compressor can effectively handle a wide variety of air tools, such as brad nailers, air guns, and even blast cabinets, which require robust air compressors that provide continuous air. The Quincy air compressor comes with a built-in thermal overload to avoid overheating. At the same time, the flywheel is manufactured out of balanced cast iron for energy efficiency and durability while the aluminium head improves heat distribution. Moreover, the finned tube intercooler helps in generating maximum cooling and also improves valve life.
The Quincy QT-54’s oil carryover (blow-by) rating is less than 5 PPM and is capable of working to a 50,000-hour pump life rating. The Quincy QT-54’s drain line is easily accessible located on one of the legs of the tank, which avoids hassles of crawling awkwardly underneath the compressors to drain accumulated moisture. The air compressor is splash lubricated and comes with an extra-capacity oil reservoir for low oil temperatures. The air compressor also features UL & CSA approval on all electrical components, and the company recommends a 50 Amp circuit breaker along with an appropriately sized wire for best performance.
If you have ever stood next to an electric air compressor, you know they are not precisely quiet machines. The Quincy air compressor is being relatively quiet, but it is not for the faint of heart. The Quincy air compressor comes well packaged in a wood crate and is shipped via freight on a pallet, to ensure it does not get damaged during shipping.
Pros
Build quality and longevity
50,000 + hours pump life
Built-in thermal overload
Less than 5 PPM oil carryover rating
Easily accessible drain line
Quiet but not super-quiet
The efficiently designed Quincy air compressor is capable of providing optimum performance cost-effectively.
Industrial Air Contractor CTA5090412 Pontoon Air Compressor
The Industrial Air CTA5090412 Pontoon Air Compressor, powered by a 5 HP Honda OHC/OHV premium residential gas engine is ideal for hard work and demanding job sites.
Driven by a direct-drive pump, the air compressor is easy to start, delivers smooth engine performance, and consumes less fuel.
The Industrial Air Compressor’s patented two-piece cooling system improves cooling efficiencies, lowers operating temperatures, and extends the life of the pump. The compact 4-gallon twin tank unit weighs 84.5 pounds and is capable of generating maximum pressure of 155 PSI. The Honda-powered air compressor can deliver 5.0 cfm at 90 psi and efficiently operate jobs such as Air Brushing, Blow cleaning, Bolting/Wrenching, Brad Nailing/Stapling, finish nailing, inflation, Roof Nailing, etc. A pontoon-style tank design with two-2 Gal. tanks for job-site portability is equipped with regulator, gauges, quick connect, and cushioned handle grips.
Made from thermally stable aluminium, the CTA5090412’s oil-free pump is designed to operate efficiently without generating too much heat at higher rpm. Additionally, the engine features an air throttle cylinder and separate pilot and check valves. This OHV engine churns out high rpm to keep the patented industrial air low maintenance pump running at peak output. The unit is portable and light enough to carry in the trunk of a car. The stock configuration works efficiently and builds pressure very fast and is not super loud. The air compressor comes with a 2-year limited warranty.
Pros
Oil-free
lower fuel consumption
Cons
Parts can be hard to find
No wheels
The handy CTA5090412 Pontoon Air Compressor packs a powerful punch in a compact size and is highly recommended for people who need a high-power machine but not have a large space area to spare.
DeWalt DXCMV5076055 60-gallon Two Stage Air Compressor
DEWALT air compressors are renowned for their build quality and performance. The DeWalt DXCMV5076055 5 HP 60-gallon two stage oil-lube industrial air compressor is designed for heavy-duty professional use. The air compressor features a heavy-duty 5 HP tops motor with a thermal overload protection system that guards the motor against any voltage fluctuations.
The DeWalt DXCMV5076055 features an ASME* air receiver 60-gallon tank and is capable of generating maximum delivery at 175 PSI, which makes it ideal to operate a wide range of tools such as impacts, ratchets, plasma cutter, sanders, and grinders while maintaining long run times.
DeWalt DXCMV5076055’s patented pump and piston design provide more cooling in running machines while maintaining consistent compression efficiency. Furthermore, the two-stage air compressor also features patented deep-grove directional and asymmetrical cooling Fins and patented cast-iron flywheel design with large extended Fins for improved cooling and low-pump RPM.
The DeWalt DXCMV5076055 comes equipped with tank pressure gauge and on/off switch and wire form belt guard. The air pressure can be efficiently adjusted with the readily accessible pressure regulator and quick-connect air outlets. The air compressor offers a 2-year comprehensive warranty on the pump, while other parts come with a 12-month warranty. The air compressor ships with synthetic blend air compressor oil for optimum performance and long life.
Pros
Excellent performance in a compact design
ASME approved product
Patented pump design provides an enhanced level of functionality
Speedy operation
Cons
The relatively shorter warranty period
Only has a 50% duty cycle
If you are looking for an industrial air compressor, which is capable of running for more extended periods while maintaining optimal efficiency, then DeWalt DXCMV5076055 60-gallon air compressor is worth a look.
Industrial Air ILA1883054 30-Gallon Belt Driven Air Compressor
The Industrial Air ILA1883054 Air Compressor is forged out of cast iron and comes with a twin-cylinder pump featuring an aluminium head & valve plate that ensures faster heat dissipation. The 1.9 hp heavy-duty induction motor is capable of delivering max psi of 155. The twin-cylinder oil-free pump system makes this air compressor extremely efficient.
The Industrial Air ILA1883054 can reach 155 PSI max pressure, but it can also dial back to as low as 40 PSI to give you optimum tool performance. The 30-Gallon ASME vertical portable tank is sufficient for continuous and demanding applications. Furthermore, the air compressor comes with pre-attached pneumatic tires for maximum portability. The air compressor motor is wired for a 120-Volt outlet, and can also be converted for 240-Volt applications. The front handle offers easy transportation to various job sites.
The air compressor comes equipped with a one-piece cast iron crankcase, thermally stable cast iron cylinder body, automotive-style ball bearings, durable Swedish stainless-steel reed valves, oil level sight glass, and easily accessible oil fill. The air compressors’ onboard controls provide easy access to the quick-set regulator, tank and working pressure gauges, and on/off switch. The unit is shipped with synthetic air compressor oil for optimum performance and long life. The ILA1883054 compressor comes with a host of safety features and is UL- and CSA-certified and is covered by 2-year limited warranty on the compressor.
Pros
Portable 30-gallon air compressor
Dual-voltage option
An oil-free twin-cylinder pump system
UL- and CSA-certified
Cons
Heavy and noisy
The high performing Industrial Air compressor is one of the best 30-gallon air compressors around in the market.
How to choose the best commercial air compressor for your needs
Choosing the right compressor will enable you to optimize production and efficiency at a maximum. Since air compressor comes in a wide variety of shapes, sizes, types, and power sources, it will be beneficial to zero in on the exact requirement to have the best fit available. Some of the crucial things to consider:
Efficiency: Air compressors are powered by fuel, which is an ongoing operating expense for your business. Choosing an energy-efficient machine will help you keep costs and carbon footprint low.
Maintenance: If the compressor is down for service, you cannot maintain optimal productivity. A sound air compressor system will require as little maintenance as possible, so you can keep your crew working and production lines running.
Warranty: Look for products that come with a long period of warranties. Also, check if there is extended coverage available.
Service: Check if the manufacturer provides support and replacement in case of a breakdown in the air compressor.
Manufacturer: A professional manufacturer would provide enormous benefits in terms of quality material and post-sale support, as compared to going for a cheaper non-branded item that might be prone to breakdown.
Frequently Answered Questions
Q: How often until a new compressor is ‘broken in’?
A: Air Compressors do not require to be broken in. Post-installation, check for any leaks or malfunctions.
Q: How often should I service my compressor?
A: If you are using the compressor for occasional jobs, then an annual service should service. However, if it used for daily heavy-duty use, then it should be serviced at least every quarter for preventive maintenance.
Q: How often should the compressor oil be changed?
A: To operate efficiently, compressor oil should be changed at regular intervals to keep it working efficiently. For a rotary screw compressor, an oil change should occur every 6000 – 8000 hours, based on the type of fuel used. For a reciprocating compressor, it would be ideal for changing the oil every three months subject to manufacturer’s recommendation.
Q: How often should the filters be cleaned or changed?
A: Air compressors with air intake filters should be cleaned weekly, depending on the degree of dirt and grunge in your facility. If the filter builds up a lot of residues or has tears or holes, then it shall be replaced immediately.
Q: What Is the Correct Voltage for Air Compressor?
A: For smaller air compressors, generally, 110 volts is sufficient, while a large compressor may consume as much as 460 volts.
Q: How to Drain Water from the Tank?
A: You can drain your tank water manually or purchase an automatic drain valve to remove the water that is air actuated, electronically actuated, or timed sequence actuated. You can also consider buying an air dryer if it is becoming too much of a hassle.
Q: Is Compressed Air Harmful?
A: Compressed air is safe when used correctly. Canned air contains chemicals that can cause damage when inhaled or ingested.
Compressed air blown directly onto the skin can obstruct an artery while inhaling compressed air can rupture your lungs. Furthermore, compressed air blown directly into the ear can rupture eardrums and may cause brain damage. These mishaps don’t happen frequently and are entirely preventable. You should not be directing the compressed air at yourself or anyone else, including cleaning clothes, blowing dust or blowing it on friends.
Q: How to decide the installation place for the air compressor?
A: reciprocating compressor can be installed easily, but you should take some precautions when zeroing in on an installation site. Please always refer to the instruction manual that is supplied with the air compressor.
Things to keep in mind while deciding a place:
Level floor and vibration mounting pads
The air compressor should be installed in a well-ventilated space
The compressor should have sufficient clearance from the walls to felicitate airflow.
The shipping skid must not be used as part of the mounting base.
Q: How to use compressed air that is stored at a higher pressure for lower air pressure work requirements?
A: You can install a pressure regulator, which would adjust the air pressure as per the requirement of the tool.
Q: What type of oil should be used in the reciprocating compressor?
A: You should only use non-detergent oils that have been designed for use in reciprocating compressors. Please note that Detergent oils must not be used in the air compressor as they create foam and cause excessive oil carryover past the piston rings and do not provide the required lubricity for the moving parts.
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