Maintaining your peace of mind

Air Compressor Maintenance 

Let’s face it. At some point, no matter how high quality the product is, equipment or machinery will break down. Breakdowns can have major impacts on the efficiency of your production which in a worst-case scenario, can cost your business thousands of dollars. While breakdowns are inevitable, regular and professional air compressor maintenance assures the reliability and quality of your equipment.

So why should I invest in maintenance?

With regular maintenance, you lower the risk of your compressed air system breaking down which ultimately leads to lower profitability. Think of your air system like a car being serviced. Filters and fluids are replaced, cooling water is inspected, belts are adjusted, and leaks are identified and repaired. These regular checkups ensure your compressed air system remains reliable throughout its lifetime.

Without servicing, system integrity could be compromised when undetected problems deteriorate, leading to damage. At some point, this will cost you a lot to repair.

Can’t I just pay for maintenance when I need it?

Sure, but keep in mind that you’ll have to closely monitor your compressor’s service requirements and order each service separately. A slow procurement process can lead to a delayed service which potentially means an increase in overall costs.

What are the risks of delaying my maintenance checks?

Most parts within your compressed air system have a specified lifespan. Failure to replace them on time can impact your compressor’s overall efficiency and reliability. Not only does this increase ongoing production costs but also the chance of a breakdown occurring which can have an even bigger impact on profitability.

How do energy costs affect my budget?

The biggest part of the total cost of ownership for compressed air equipment is energy consumption. If you fail to properly maintain your air compressor system, pressure drops may occur, decreasing the system’s efficiency.

During an average compressor’s lifetime of around 10 years, the cost of compressed air is roughly divided up as 73% energy costs with the remaining 27% divided between capital costs, installation and maintenance. In reality, producing 1 kW of compressed air requires 8 kW of electricity. So, if you’re not evaluating the energy performance of your system, you are potentially converting your money into thin air.

How often should my receiver be inspected?

Under the Occupational Safety and Health Regulations 1996 requirements and AS/NZS 3788:2006, routine biennial inspections of pressure vessels is mandatory. 

Pressure vessels used in the workplace present a lot of potential dangers when not properly maintained which can cause damage to property, injury and even death. This is why it’s essential to properly install and service receivers and ensure that all of your equipment complies with the relevant AS standards and Worksafe WA regulations.

Do I have to register my receiver?

As per the Occupational Safety and Health Regulations 1996 along with AS/NZS 3788:2006, registration of pressure vessels is mandatory in order to assess safety and to detect any dangerous deterioration.

Interested in learning more about Nessco Pressure Systems servicing and maintenance capabilities? Then get in contact today. 

Making the right choices when choosing your Compressor System


A lot of careful planning goes into the decision to purchase an air compressor system. Buyers have to contemplate a variety of factors including the amount of air pressure needed, what type of system fits their needs and how much they are able to invest in a system.

If you don’t have the knowledge and experience that Nessco Pressure Systems has when choosing the right system, mistakes can be made when selecting what to buy which can cost you in the long run. 

Let us help you out by pointing out some of the things to look out for when selecting your compressor system.



Deciding on the correct size of compressor is key to the efficiency of your business. The wrong size can lead to problems with production and wasted energy which can increase overall costs. It’s also wise to plan ahead and think what may be your needs in the future.


One of the key determinants to selecting size is the amount of pressure required. Your air compressor has to be able to provide enough air pressure so that you are able to complete the task at hand. Anything less will not work, rendering your system useless. This is why it’s important to know the pressure that is required beforehand so that you are able to choose a powerful enough compressor.

Air Flow

Another important factor to consider is the correct air flow needed for the compressor. To put it simply, flow is the ability of the compressor to perform a task within a given time period. The amount of flow needed is determined by the length of time required to complete the task. If your flow isn’t sufficient enough, your compressor will need to build up pressure inside its reserve tank which suggests that the compressor you’ve chosen might be undersize. Again it’s important to know your requirements before making a choice.

One of the best ways to figure out the correct flow needed is to perform a compressed air audit which can be conducted by our knowledgeable NPS staff.

Contact NPS about a Compressed Air Audit

Future Expansion

It’s also important to consider what your air usage might be like in the future when making your decision. While your current air pressure needs might be small, a company that plans ahead and selects an air compressor that will account for the growth of their business can save themselves a considerable amount by not having to purchase subsequent compressors systems.



The type of compressor your business needs is another factor you need to consider at decision time. Two of the more popular options available are piston and rotary screw compressors.

Piston Compressor

The piston compressor is one of the most economical options available. This is a small and robust air compressor that is often used in small workshops, tire shops or manufacturing facilities. One of the highlights of the piston compressor is that they are relatively easy to maintain and usually require minimum investment however this doesn’t mean you should buy one this instant!

Piston compressors are designed for intermittent use which means it can only work about 50-60% of their duty cycle. These units also need time to cool off between their cycles otherwise they will overheat and fail. Another factor to consider is that piston compressors can be extremely loud when operating, so you may want to take into account whether any employees will be working close by.

Rotary Screw Compressor

The rotary screw compressor is designed for operations that require a constant compressed air supply. While piston compressors may only need to be in use for 50% of their duty cycle, rotary screw compressors may be used up to 100% of their duty cycle and are generally built to have long, reliable lifespans. The amount of popularity for screw compressors means there are plenty of options available which suit a range of budgets and needs.

View our range of Rotary Screw Compressors


So these are a few factors to consider when choosing which air compressor system is right for you. If you’re looking for more advice or information about which system would be right for you, you can get in contact with one our friendly staff who are able to use their extensive knowledge and experience to find the solution for you.


If you’re looking for more information, get in contact with Nessco Pressure Systems today. 

Can Your Compressed Air Dryer Cope This Summer?


Overheated System = Production Down Time


Like us, your compressed air system can sweat in the warmer months! Air Dryers can act like an air conditioner to your airline; eliminating condensation due to humidity, and therefore preventing damage to your expensive equipment.


As the months get hotter some compressed air dryers don’t function as well leaving unwanted residual moister. Excessive water in compressed air, in either the liquid or vapour phase, can cause a variety of operational problems for users of compressed air. These include freezing of outdoor air lines, corrosion in piping and equipment, malfunctioning of pneumatic process control instruments, fouling of processes and products, and more.


If your compressed air dryer is overheating this summer consider the following questions and contact Nessco Pressure Systems.


1. Is your dryer the right size/design for your application and conditions?

When selecting the correct dryer you must consider the level of moisture required to be removed from the compressed air for that specific application. If your dryer is not sized correctly for a particular system then issues such as overheating, decreased efficiency and shut-down can result.


2. Is your dryer in the correct location?

The performance of the dryer will improve if installed in a cooler well ventilated station.


3. Do you have the correct Filtration?

Filters work with compressed air dryers to remove water and other contaminants from the compressed air and prevent component contamination. Three types of filters are typically used; Particulate, Coalescing and Absorption.


4. Is your compressed air system and dryer properly maintained?

Keeping your equipment and machinery running at a consistent high level of performance is important to every industry; breakdown of vital machinery in the workplace equals lost time and money. Air dryers and filters keep your compressed air system operating efficiently, but only if they are properly maintained.


Call us today on 1300 290 638 for any of your compressed air equipment needs.

Why Your System Needs A Compressed Air Dryer

A Compressed Air Dryer is used for removing water vapour from compressed air.


Humidity is a component of atmospheric air, which can be found in the form of condensate and/or vapour in compressed air distribution systems and the machines that use the compressed air.


If the condensate can be easily separated and discharged, humidity, in the form of vapour, will follow the compressed air flow all the way to the final product. When it then cools, a part of this humidity present in the compressed air condenses and over time causes serious damage to the distribution network, the machines using the compressed air and the final product.



How Air Dryers Work


For example, 5.1 l/h of condensate is separated from a compressor with an output capacity of 10 Nm3/min and an ambient intake air temperature of 20°C and 70% relative humidity, whilst operating at a delivery pressure of 8 bar (g) and cooling the air to 30°C.



If the compressed air is then dried even more to a dewpoint of +3°C, a further 1.7 l/h of condensate can be separated.


If you require a new Dryer please contact our NPS Compressed Air Equipment Specialists on 1300 290 638.



Ten Things to Target During an Air Audit to Ensure Compressed Energy Savings

Compress Energy Costs through Air Audit


With the rapidly escalating cost of electricity, there is an increasing focus within industry on the energy consumption of air compressor systems. As an un-maintained system can be wasting as much as 50% of a compressor’s output, it is important to ensure that your system is operating at its full potential.


A compressed air system audit can provide an important means of establishing the efficiency of systems and identifying precisely where energy losses are occurring. An audit will highlight the true costs of compressed air and identify simple opportunities to improve plant and process productivity, on-site safety, product quality, equipment reliability and plant downtime.


Things to target during an air audit to ensure compressed energy savings;


1. Plug those leaks and save


Studies indicate that as much as 50% of the compressed air produced in today’s industry is wasted to leaks. Identifying and correcting these leaks may save not only the purchase price of a compressor, but also reduce the amount of energy needed to run it.


It has been our experience that plants which have no disciplined compressed air leak-management program will have a cumulative leak level equal to 30-50% of the total air demand. This means that every 8-12 cfm leak can cost you $800-$1,200 per year.


NPS audits offer a leak inspection program so that every sector of the plant is inspected once a quarter to identify and repair leaks. Read more here.


2. Double-check air requirements


Often, production overestimates the amount of air it needs, resulting in an inefficient system.


More often than not, it is one process that needs a certain minimum pressure, affecting the pressure requirements of the entire system. For example, while the majority of a plant may only require 80 psi, the compressed air system may demand 98 psi.


In cases where only a small area of the system needs higher pressure, an effective solution is to set up a secondary, smaller, high-pressure unit or an appropriate booster, rather than driving the entire plant system at the higher pressure. Expecting the supply system to support a black hole is not a realistic design criterion.


3. Connections all teed off


One of the simplest fixes in a compressed air system is to replace tee connections with directional angle entry connections.


In a piping system where a feed line of compressed air is trying to feed into another airline, the turbulence caused by a 90 ° entry often causes a 3-5 psi pressure loss. Such a loss can cost you at every one of those tees.


More importantly, in a compressor house, the back pressure sends a false unload signal to the controls, causing premature unloading or extra compressors to be on-line. Using a 30-45° directional angle entry instead of a tee will eliminate this pressure loss, with the extra cost of the directional entry negligible.


4. Bad piping


Convoluted piping, piping restrictions, old pipes and incorrect pipe sizes often lead to pressure loss.


In a well-laid-out system, the interconnecting piping from the compressed air supply to the process and header distribution piping should create no pressure loss.


Piping is a major consideration, especially in older facilities or shops that have grown and expanded. Cast-iron piping will rust dramatically over time, releasing rust and scale into the compressed air system and creating build ups at various points in the system. In many cases, it is easy to simply replace a section of pipe to gain efficiency. When upgrading, ensure that the physical piping diameter is sized to deliver the required air flow with minimum pressure drop.


5. Down with over pressurisation


Excessive pressure increases leaks and wastes money.


Some end users will try to increase pressure in an attempt to compensate for capacity issues, however this in fact has the opposite effect on air flow, often exacerbating the problem. Additionally, there is a proportional relationship between pressure and power consumption, for which every 10 psi in excess pressure results in a 5% increase in power cost.


Too-high a pressure will amplify system problems, not solve them. Lower system pressures means less required mass, therefore fewer running compressors and lower overall running costs.


6. Insufficient storage


Insufficient storage is a common problem.


Across the board in manufacturing and processing, the value of an appropriately sized air receiver and appropriate compressed air piping is underestimated.


These tanks provide a first stage of moisture separation to help maintain compressed air quality. However, their primary function is storing and delivering compressed air to help meet periods of peak demand and to prevent excessive compressor cycling.


7. Inappropriate use


Unregulated and inappropriate use of compressed air wastes a lot of energy.


Considering that it costs eight times as much to use air as it does to use electricity, it is prudent to re-evaluate unregulated air-powered cabinet coolers, blow-offs, vacuum generators, mechanical pumps, air motors and hoists, vibrators, aeration, spraying and a host of other equipment.


Open blow, refrigeration and vortex cooling may all be replaceable with heat tube cabinet coolers with a potential savings of 3.5-4 kW each on a 30- by 24- by 12-inch average cabinet. In addition to this, venturi air amplifier nozzles or air inducers are recommended whenever possible, reducing blow-off compressed air by 50% or more.


8. Pumps and pule cleaners


Air-operated diaphragm pumps tolerate aggressive conditions relatively well and can run dry, which makes them a favourite with plant personnel.


But is an air-operated pump the best solution? Electric motor-driven diaphragm pumps are readily available, and may work just as well.


If air-operated pumps are needed, consider adding controls to shut the pumps off when they are not needed. Pumps waste the most air when they are pumping nothing.  Additionally, check to see if the pump is running at the lowest possible pressure. Simple controls can increase pressure when needed.


9. Get rid of obsolete restrictions


Clogged filter elements, forgotten manual drain traps and neglected separator cartridges can cause significant drops in pressure and negatively impact capacity and reliability, not to mention creating air-quality issues.


One often overlooked item in the air piping system that causes pressure loss is equipment that is left installed but is no longer in use. Such things as old, unused orifice plate flowmeters, filters and separators are often left in the air system even though they are no longer required. Since they are not used or maintained, they fill with sludge, rust, and scale, causing ever-increasing blockage and pressure drop as the air flows past. This requires a corresponding increase in header pressure to maintain the required process pressure.


10. Maintain the system


Poor air quality adversely affects overall plant operations.


Air should be clean, oil free and dry, however to achieve this requires regular maintenance of the filters, separators and driers. Neglecting recommended maintenance can let oil get into the plant air and cause production problems such as dripping tools and fisheyes in paint systems.


Change air/oil separators, filters and other components at the optimum time and on a regular basis, not when they clog up and cause a pressure loss problem.


Air Audits by NPS


Nessco Pressure Systems offer a complete visual compressed air system audit, which may detect and identify problem areas. Our tailored audits have been proven to be extremely effective in increasing system production and providing significant cost savings. The cost of an audit may well be the best investment you have made, potentially saving you thousands of dollars a year in energy and production costs.


To ensure you are not spending more than you need to, our experienced service technicians can perform an efficiency audit on your system. Our audit involves a comprehensive report, with recommendations for a scope of work to improve your running costs. Call us on 1300 290 638 for more information!


Book Your Air Audit Today

Case Study 8 | NPS Slices Energy Costs at D’Orsogna

Case Study 8 | NPS Slices Energy Costs at D’Orsogna


Local legends D’Orsogna, synonymous with high quality flavoursome meat products came to Nessco Pressure Systems with concerns over air quality, pressure loss and electricity bills. Like most leading food and beverage wholesalers and manufacturers, their factory relies heavily on compressed air.


NPS undertook an Air Audit mapping D’Orsogna’s airline and recording the current four compressors’ operating patterns.
A fully comprehensive report was generated from the Air Audit results. Included in this report was an outline of the potential savings D’Orsogna could achieve from simply replacing their four conventional load/unload compressors with one frequency driven variable speed compressor (IVR). A frequency driven compressor adapts itself to the production’s air requirements, saving on average 25-35% in electrical costs. Read more about IVR Variable Speed Compressors here.


Following a consultation of the Air Audit results with D’Orsogna, a solution was provided which comprised of a new high efficient variable speed 90kw compressor system, an oversized refrigerated dryer, pre & coalescing filtration along with a 3000L air receiver. Once located, the equipment was connected via our Infinity Aluminium Airline system. This was also used to convert the existing airline to a ring main system to supply a consistent pressure, flow and a high-quality grade of compressed air to the factory.


D’Orsogna understands that in some areas of the production process a higher quality grade of compressed air is required as per ISO8573. The quality of air must be regularly controlled, monitored, and tested to ensure compliance. D’Orsogna is extremely conscious of these standards with a well-established quality management system. NPS worked closely with D’Orsogna to identify all points where a higher quality grade of compressed air is required and installed a bespoke adsorption dryer and filtration system to ensure the high standards and integrity of their products and processes are upheld.


During the consultation process, it was also clear how conscious D’Orsogna were about their environmental impact, including waste oil disposal so NPS included a large Oil Water Separator in the project which processes the condensate discharged from dryer, receiver and filters to ensure correct disposal of waste oil.


35 new safety airline droppers will also be installed throughout the factory which features air fuses and safety support cables.  If a hose failure occurs, the air fuse is designed to eliminate potential injury to employees and damage to the production area by minimising the whip effect of the hose.


Nessco Pressure Systems worked closely with D’Orsogna to create a compressed air system that is reliable, energy efficient and provides the flow and pressure required by the factory while ensuring the correct quality grade of air for their products demand.



“Nessco Pressure Systems was a pleasure to work with and were on time and on budget. The installation went really well and the project also fits perfectly with our sustainability agenda as saving energy is one of our top priorities. The compressors are working very efficiently and delivering a high specific output of clean quality air.”

– Neil Harvey, Chief Engineer



This installation was directed by our business development manager, Dillon Smith. Dillon specialises in creating turnkey, compressed air systems that are tailor-made for the needs of Western Australian companies.


If you would like more information about our compressed air solutions or to book in an Air Audit, contact Dillon Smith on 0412 169 430 or email at