Industry-leading efficiency and low cost of ownership for the automotive industry
ELGi is a leading rotary screw air compressor manufacturer that offers a range of oil-lubricated compressors and oil-free screw compressors that match the varying requirements of the automotive industry. ELGi’s industrial compressors are backed by cutting-edge technology that provides industry-leading efficiency and low cost of ownership for the automotive industry.
TO THIS INDUSTRY
APPLICATIONS OF COMPRESSED AIR IN THE AUTOMOTIVE INDUSTRY
Industrial compressors play a pivotal role in facilitating a multitude of processes within the automotive industry, serving as integral components for various applications. In Europe, automotive manufacturers entrust ELGi's industrial air compressors—comprising both reciprocating compressors and screw-type compressors—to meet the diverse and demanding needs of their operations. These compressors are instrumental in supporting numerous critical applications, ensuring the efficiency, precision, and reliability required in the automotive manufacturing environment. Some key applications include:
Painting and Coating: ELGi’s air compressors for the automotive industry are used for automotive painting. These rotary-type compressors power paint sprayers, ensuring a smooth, consistent application of paint and coatings, which is vital for achieving a high-quality finish on vehicles. It is recommended to utilise oil-free compressed air according to ISO8573-1 for applications that involve painting and coating to ensure no contamination in the compressed air, for a high finish.
Assembly Line Tools: Many tools used in automotive assembly lines are powered by air compression systems. ELGi’s rotary screw compressors power impact wrenches, air ratchets, and screwdrivers for assembling and disassembling vehicle parts with precision and speed.
Air-Operated Robots: Robots play a significant role in the automotive industry. Many of these robots require compressed air to operate. ELGi's screw-type compressors are used to power robots for welding, lifting, and precise parts placement.
Tire Inflation: Air compression systems inflate tires in automotive production. Correct inflation of tires is crucial for vehicle safety and performance.
Dust and Fumes Extraction Systems: Compressed air is essential in operating the air dust and fumes extraction systems that keep the manufacturing environment clean. ELGi’s screw-type air compressors help remove dust and debris, ensuring a contaminant-free space, which is critical for some steps in vehicle production.
Pneumatic Material Handling: In automotive factories, material handling equipment like hoists and conveyors often need compressed air for operation. These tools are vital for transporting heavy parts and assemblies across the factory floor.
Quality Control: ELGi’s air compression systems are used in various quality control processes, such as leak testing, to ensure that vehicle components meet the specified standards.
Cooling and Drying: Compressed air is used to dry the product after the washing and painting step. Air compression systems are also used for cooling purposes in various manufacturing stages.
The importance of consistent airflow for the automotive industry
ELGi is among the leading global oil-lubricated and oil-free air compressor manufacturers. Various automotive manufacturers rely on ELGi's wide range of air compressors for the automotive industry. Automotive manufacturers rely on ELGi’s air compressor solutions as they provide consistent and reliable airflow with the lowest cost of ownership and industry-leading efficiency. Consistent airflow is critical for the automotive industry, impacting production efficiency, product quality, and safety.
Consistency in Production Processes: Automotive manufacturing involves several precise and repetitive processes. Consistent airflow and pressure are essential for maintaining the uniformity and quality of these processes to ensure a high-quality final product. Fluctuations in air pressure can lead to inconsistencies in assembly, painting, and tool operation, potentially causing defects.
High-Quality Surface Finishing: Spray painting and coating require consistent airflow to ensure a smooth and even application. Variations in air pressure can lead to imperfections in the paint finish, such as runs or sags, resulting in additional resource consumption to fix these issues.
Efficient Operation of Pneumatic Tools: Many assembly line tools are pneumatic and require steady air pressure for optimal performance. Inconsistent pressure can lead to reduced tool efficiency, increased wear and tear, and a higher risk of tool failure, disrupting production and increasing maintenance costs.
Automation and Robotic Precision: Modern automotive plants use automated robotic systems that rely on compressed air for movement and operation. Fluctuations in airflow and pressure can impair the precision and efficiency of these robots, leading to production issues.
Safety Considerations: Reliable and stable air flow is crucial for ensuring safety in the workplace. Sudden pressure drops can lead to accidents or malfunctions in equipment, posing risks to workers and the production environment.
Energy Efficiency: Compressors that deliver stable air pressure without frequent cycling on and off are more energy-efficient, reducing operational costs and the environmental footprint of the manufacturing process.
Reduction in Downtime: A reliable compressor minimises the chances of breakdowns and operational interruptions. This reliability is crucial for meeting production targets and maintaining a streamlined manufacturing process, as downtime in automotive production can lead to significant financial losses.
ELGi Air Compressors for the Automotive Industry
ELGi's Air Compressors for the Automotive Industry symbolize a strategic alignment between advanced air compressor technology and the complex requirements of automotive manufacturing, facilitating a seamless and efficient production environment for this dynamic industry. ELGi’s different air compressor types support a wide range of functions in the automotive industry. From oil-lubricated to oil-free industrial air compressors, there is an ELGi air compressor for every requirement in the automotive industry.
AB Series Oil-Free Screw Air Compressor
Class-0 certified as per ISO 8573-2010
The AB Series has consistent oil-free air, meeting ISO8573-1 class 0 oil standards. Pipes have special e-coating, providing consistently clean and oil-free air and optimised rotor clearances, ensuring consistent air delivery.
Corrosion-resistant stainless steel rotors
ELGi air compressors use FDA-approved stainless steel with a proprietary coating, eliminating any chance of corrosion.
Pure water quality complying with IS:10500-2012
ELGi screw compressors have a closed-loop water circuit to maintain water quality, eliminating the need for an RO system. This reduces power and maintenance costs and ensures pure water quality, complying with IS:10500-2012.
Viable microbiological content complying with ISO 8573-7:2003
The compressor discharges air without microbiological contaminants, complying with ISO 8573-7 standards
Best-in-class maintenance cost
The efficient rotors have best-in-class performance, single-stage operation, low operation speed, application-oriented design, and lower overall maintenance.
OF Series Oil-Free Screw Air Compressor
ISO 8573-1, Class '0' oil-free air
Our oil-free screw compressor has consistent oil-free air, meeting ISO8573-1 class 0 oil standards. A food-grade coating is done where air contacts the metal surface inside the compressor, ensuring consistent oil-free air without metal debris. Pipes have special e-coating, providing consistently clean and oil-free air and optimised rotor clearances, ensuring consistent air delivery.
Indigenously designed and manufactured airends
ELGi is one of the few air compressor manufacturers to design and manufacture oil-free airends. With our in-house oil-free technology, the compressors are engineered to deliver maximum uptime and reliability. ELGi's unique η-V rotor design reduces pressure losses and increases stage efficiencies, leading to an optimised compressed air system.
PTFE air end coating for efficiency and long-term reliability
ELGi's airend rotors and housing are coated with PTFE-based food-grade PP coating to resist corrosion and endure temperatures up to 250 degrees Celsius. This results in optimum long-term performance with no loss in efficiency.
ELGi's OF Series two-stage oil-free compressors come with a superior warranty. The compressor is built to ensure long life, reliability, and durability.
Best-in-class maintenance cost
The Rack and Pinion capacity control system can power over one million cycles without maintenance. It allows the machine to operate numerous cycles in a minute with a reduced pressure band. This saves energy and maintains pressure discharge. This feature considerably lowers the cost of ownership.
EG Series Screw Air Compressor
Highly Efficient Proprietary Airend Design
The ELGi EG Series screw air compressors are equipped with patented airends that have in-house developed η-V profile rotors and a 4/5 lobe combination. ELGi is among the few screw compressor manufacturers to design and develop its own airends. The rotors in the EG Series oil-injected rotary screw compressors are designed to run at low speeds to increase the efficiency and life of the air compressor. The proprietary airend supplies compressed air for all demanding applications while ensuring minimal environmental impact.
Highly Reliable and Efficient Motors
The motors in the EG Series oil-lubricated air compressors have a larger core and increased windings to provide better thermal management. Additional fins on the face of the motor with the lowest air block over the frame offer better reliability and performance.
Advanced Package Design
The EG Series oil-lubricated air compressors package is configured with subsystems designed to minimise system losses and maximise energy savings. While the design offers easy serviceability, the aesthetically built acoustic enclosure keeps the noise levels in check.
Robust and Reliable Under Extreme Conditions
The EG Series oil-lubricated air compressors are robust and reliable. They are designed to perform at extreme temperatures in manufacturing applications, from cold to hot, and from dry to extremely humid conditions with ambient temperatures of up to 50°C.
Ensure Complete Peace of Mind for Every Manufacturing Application
The EG Series oil-lubricated air compressors provide our customers with an industry-leading warranty of 10 years* on the airend with no limitation on running hours, a 5-year package warranty, a 3-year warranty on VFD, and one year on rubber, electrical, and plastic parts.
*Terms & Conditions apply.
EQ Series Oil Lubricated Screw Air Compressor
The EQ Series oil-lubricated air compressor is built to perform reliably in tough conditions. The compressor operates in dusty environments and humid conditions with an ambient design of 50°C.
Long Consumable Life
The EQ Series rotary-type compressor benefits from an extended consumable life and minimum maintenance. Components that need maintenance are easily accessible thus making service simple and efficient.
Reduced Starting Load
The EQ Series’ intake valve is designed to reduce the starting current. When working with the optimised blow-down valve, unload power is significantly reduced, resulting in greater savings.
Energy Efficiency with Optional VFD
When your application demand fluctuates significantly, the optional inbuilt VFD in the EQ Series industrial compressor will ensure significant energy savings.
Easy to Use Industry Grade Controller
The smart Neuron XT controller on the EQ Series is easy to operate and has advanced fail-safe features. Neuron XT protects the compressor from major failures occurring due to motor overload, reverse rotation of the motor, high air/oil temperature, and high pressure.
EN Series Screw Air Compressor
ELGi EN Series screw-type air compressors are designed to encapsulate all functional components of the compressor within one common housing. The encapsulated design allows for easier maintenance and reduces the noise generated, while the integrated components improve the equipment's reliability.
The EN Series oil-lubricated compressors have a small footprint. This, along with its high reliability and low maintenance requirements, makes the EN Series rotary screw air compressors ideal for small and medium-scale manufacturing applications.
ELGi is among the few compressed air manufacturers to have an advanced airend design. The EN Series rotary screw air compressors are powered by ELGi's proprietary air ends with an energy-efficient η-V profile and 4/5 lobe combination, which provide maximum efficiency and uninterrupted performance.
Ease of Maintenance
The EN Series oil-lubricated air compressor has a single service door access to routine maintenance points and a spin-on oil filter and separator for fast and easy regular service.
Robust Cooling System in High Ambient Temperatures
The EN Series screw compressor is built to operate in high ambient temperatures in manufacturing applications of up to 45°C, with major components designed for 50°C. Its unique air-cooling system comes with separate hot and cold zones, ensuring a longer life for the compressor. In addition, the high-efficiency coolers and cooling fans ensure low operating temperatures, better energy conservation, and longer operations.
Low Noise Levels
ELGi EN Series screw compressors are known for their low noise levels. At 65 dBA, the EN Series offers one of the lowest sound levels in the industry. The reduced noise levels foster improved communication, concentration, and employee well-being.
Why choose ELGi for your automotive manufacturing?
Proprietary Technology: ELGi is one of the few air compressor manufacturers in Europe to design and develop its airends. ELGi oil-free screw compressors are equipped with our in-house oil-free technology for maximum uptime and reliability. The proprietary η-V rotor design from ELGi minimises pressure losses and improves stage efficiency, resulting in a more efficient compressed air system. Slower rotor speeds mean less wear and tear, less vibration, and more stable long-term performance.
Superior Warranty: ELGi air compressors are backed by an outstanding warranty, reflecting their commitment to long life, reliability, and durability.
Low Maintenance Costs: The Rack and Pinion capacity control system can endure over one million cycles without maintenance, saving energy and maintaining consistent pressure discharge, further lowering ownership costs.
Reliable Working Conditions: The compressors feature rigid stainless-steel tubes for reliability and an innovative design that operates effectively in a wide temperature range, from -5 to 45 degrees Celsius, ensuring reduced maintenance costs.
Low Cost of Ownership: The high energy efficiency design, low-pressure cooling-water heads, and smaller water pumps optimise power consumption, enhancing efficiency and offering a quick return on investment by lowering operating costs.
Guide to Choosing the Right Air Compressor for the Automotive Industry
Determine the Appropriate Air Volume: Calculate the required compressed air volume by calculating the required pressure and the hose or pipe size. Ensure the air compressor's supply matches the volume of air needed for optimum efficiency.
Consider the kW Rating of the Compressor: An air compressor's kW rating indicates the volume of compressed air it can produce at a given pressure. It is essential to match the power with the application's requirements to ensure the highest performance efficiency and lowest energy consumption.
Quality of Air: Ensure the compressor provides the necessary air quality, with filters and dryers if needed for paint applications. Specific applications like spray painting require compressed air free of oil residue. In such cases, an oil-free air compressor must be used.
Maintenance and Reliability: Look for compressors with low maintenance needs and high reliability to minimise downtime and maximise efficiency. ELGi air compressors are known for their reliability and low maintenance requirements, which reduce the cost of ownership.
Evaluate Available Space: Measure the available space and compare it to the dimensions of the air compressor. Ensure a seamless fit to optimise the performance of your air compressor solution.
Noise Level: Evaluate the noise tolerance in your manufacturing environment. ELGi air compressors have noise reduction features that might be crucial for quieter operation.
Future Expansion: Consider future needs and any planned expansion while selecting a compressor to scale the compressed air supply with increased demand.