@air
2025-03-24
How to choose an oil-free lubricated air compressor for glass bottle production
In the glass bottle manufacturing industry, compressed air systems serve as a key power source, directly affecting product quality, production efficiency and operating costs. With the upgrade of air cleanliness requirements in ISO 8573-1:2010 and the global focus on sustainable manufacturing, oil-free lubricated air compressors have become the core equipment choice for modern glass bottle production.
1. The strict requirements of glass production technology on air quality
1.1 Raw material conveying and mixing systems
- key parameters: Required to meet ISO 8573-1 Class 0 oil-free certification
- technology needs: Compressed air directly contacts raw materials such as quartz sand and soda ash, and oil pollution will cause:
- Caking of raw materials (oil particles with a particle size of>0.1μm will trigger a chemical reaction)
- The error of ingredients proportion is>0.3%
- Furnace thermal efficiency drops by 5-8%
1.2 Forming section (IS Machine)
- pressure requirements: 0.7-1.0 MPa constant pressure gas supply
- cleanliness standard: Oil mist content must be <0.01 mg/m³ (compliant with FDA 21 CFR 11 regulations)
- failure consequence：
- Oil film on the mold surface increases the molding defect rate by 12-15%
- The carbon deposition from the shear nozzle causes the product wall thickness deviation>0.2mm
1.3 Annealing furnace control system
- temperature sensitive: Level 0 oil requirement (residual hydrocarbons <0.003 ppm)
- thermodynamic influence: Oil vapor can reduce heat transfer efficiency by 8-12%, causing annealing curve to shift
1.4 online detection system
- optical detection: 100% oil-free air is required (oil mist will increase the CCD misjudgment rate by 30%)
1.5 Pneumatic device for packaging line
- energy efficiency requirements: Comply with ISO 50001 energy efficiency level II standard
- hygienic standard: Meet EHEDG Class EL-3 certification
2. Selection criteria for core parameters
2.1 pressure characteristics
| process links | Pressure range (MPa) | fluctuation tolerance | Recommended model |
|---|---|---|---|
| raw material treatment | 0.6-0.8 | ±1.5% | two-stage compression |
| Forming machine drive | 0.8-1.0 | ±0.5% | frequency conversion control |
| testing equipment | 0.4-0.6 | ±0.2% | Precise voltage regulation |
2.2 Traffic matching calculation
Total demand flow = ∑ (equipment air consumption × utilization factor) × 1.2 (safety factor)
Typical configuration examples:
- 8 sets of double drop molding machines: 120-150 m³/min
- Annealing furnace control: 20-30 m³/min
- Auxiliary equipment: 15-20 m³/min
2.3 energy efficiency indicators
- specific power: Should be ≤6.5 kW/(m³/min)(complies with ISO 1217:2016 Annex C)
- IPLV value: Comprehensive part-load performance ≥ 45%
2.4 thermodynamic parameters
- Isotropic efficiency: ≥ 80%(water-lubricated bearing technology)
- Exhaust temperature: ≤ ambient temperature +15 ℃ (no need for post-cooling)
2.5 material compatibility
- Rotor coating: HVOF tungsten carbide (hardness ≥ 1200 HV)
- Waterway system: 316L stainless steel (Cl resistance ≥ 200 ppm)
3. Potential risks of oil lubrication systems
3.1 Quality Risk Matrix
| pollution types | probability of occurrence | severity | Detection difficulty |
|---|---|---|---|
| surface grease | High (35%) | serious | readily detectable |
| porosity osmotic | Medium (18%) | deadly | difficult to detect |
| chemical denaturation | Low (7%) | serious | difficult to detect |
3.2 Cost impact analysis
- 300% increase in filter replacement frequency
- Annual additional fuel consumption cost: $8-12/m³ compressed air
- Product recall risk cost: up to 2-5% of annual output value
4. Technical advantages of oil-water lubrication systems
4.1 Quality improvement dimension
- Increase in product pass rate: +1.2 – 1.8 percentage points
- Mold life extension: 30-40%
- Reduction in detection misjudgment rate: 25-35%
4.2 Operational cost optimization
| project | oil-free system | oily system |
|---|---|---|
| Annual maintenance costs | $0.80 thousand | $32,000 |
| energy costs | $150 thousand | $185 thousand |
| Filter element replacement costs | $0.3 thousand | $21,000 |
4.3 environmental benefits
- Carbon footprint reduction: 25-30 tons of CO ˇ/year (per 100kW unit)
- Wastewater treatment costs: reduced by 60-70%
5. Technical comparative analysis
5.1 Comparison table of key parameters
| indicators | oil-free lubrication | oil lubrication |
|---|---|---|
| air cleanliness | ISO Level 0 | ISO 2-4 |
| Specific power (kW/m³/min) | 6.2-6.8 | 7.0-7.6 |
| MTBF(hours) | 50,000-60,000 | 30,000-40,000 |
| Noise level (dB(A)) | 72-75 | 78-82 |
| heat recovery efficiency | 90-95% | 70-75% |
5.2 Full life cycle cost analysis (10-year period)
| cost term | Oil-free system ($) | Oiled system ($) |
|---|---|---|
| initial investment | 520,000 | 480,000 |
| energy consumption | 1,250,000 | 1,550,000 |
| maintenance costs | 80,000 | 320,000 |
| environmental compliance | 15,000 | 85,000 |
| total | 1,865,000 | 2,435,000 |
6. Selection and implementation suggestions
- requirements analysis phase
- Conduct complete VSD gas volume mapping (continuous monitoring for ≥720 hours is recommended)
- Draw a pressure-flow characteristic curve
- system design principles
- Adopt main pipe air supply system (redundancy ≥30%)
- Equipped with intelligent dew point control system (accuracy ±2℃)
- verification test requirements
- Conduct all ISO 8573-1 testing
- 72-hour continuous load test
conclusion
In the field of glass bottle manufacturing, oil-free lubricated air compressors not only meet international quality standards and environmental regulations, but also achieve a 18-22% reduction in full life cycle costs through excellent thermodynamic performance and maintenance-free advantages. With the implementation of new standards such as BS EN 1012-3:2023, this technology will become an inevitable choice for the sustainable development of the industry.
