While it might seem that opting for a larger compressor will provide ample capacity, the reality is that oversizing leads to several long-term problems:

• Moisture Accumulation and Rust: Just as we saw with the Ingersoll Rand compressor, oversizing can cause moisture to remain in the system. The lack of sufficient heat prevents proper evaporation, allowing water to pool inside the compressor. Over time, this can cause rust and corrosion on crucial components, including screws and bearings, compromising the machine’s longevity and leading to costly repairs.
• Increased Wear and Tear: Because an oversized compressor often cycles on and off or runs at low loads, it experiences more wear and tear on essential components. This includes the motor and the screw elements, which are not designed to handle constant cycling. The end result can be frequent breakdowns and premature part replacements.
• Reduced Efficiency: A compressor that doesn’t match your specific air demand will end up wasting energy. In the case of fixed speed compressors, oversizing often means the compressor is running at full speed when it isn’t needed, wasting electricity. Similarly, a variable speed drive (VSD) compressor that is oversized will consume excess energy to produce compressed air that’s not required, resulting in increased operational costs.
• Higher Operational Costs: Not only do oversized compressors cost more upfront, but they also incur higher long-term costs due to increased energy usage and maintenance requirements. Components wear out faster, and rusted elements may require more intensive (and expensive) repairs or replacements, as we observed with the rusted screws in our customer’s unit.