Air compressors are among the most critical equipment for all industries, and like any other machine, they contribute to the noise generated in the factory.

While low noise levels are harmless, loud noises can affect workplace safety, cause hearing damage and other health issues. While sudden loud noises can disrupt the work environment, working in a noisy environment for a longer period can also cause irritation, muffled hearing, and potentially impaired hearing in the worst cases. This can adversely affect employee well-being and overall productivity.

Companies are always trying to ensure that their workers are not exposed to loud noise, not just from the productivity perspective but also concerning workspace safety. Further, the European Union has also issued directives that lay down minimum requirements for protecting workers from risks to their health and safety arising from exposure to noise, particularly the risk to hearing. Companies in Europe are subject to strict noise regulations and standards. Employing low-noise air compressors helps companies comply with these regulations, avoiding potential fines and legal issues. Quiet air compressors can be placed closer to workstations, eliminating the need for extensive piping systems and resulting in more efficient compressed air delivery. This flexibility enhances operational convenience.

When companies are located near residential areas, they should consider the impact of noise pollution on the neighborhood. Using low-noise air compressors helps to maintain good relations inside and outside of the production facility.

Understanding Noise Levels of Air Compressors

Noise is measured in decibels (dB). General human conversations are about 60 dB loud, while a music concert can cross 120 dB. Exposure to noise levels above 80 dB for extended periods can lead to hearing damage and other health issues. It's crucial to use hearing protection and implement noise-reduction measures in environments where these noise levels are prevalent. The noise generated by an air compressor depends on the type of compression technology and how the compressor is used.

Small-scale to general usage: For applications within a small-scale setting, such as inflating tires, operating airbrushes, or powering small tools, a compressor may generate about 40 to 60 dB of sound. Compressors falling in this range are used in workshops, small businesses, and environments where a moderate level of noise is acceptable.

Industrial Usage: In industrial settings, such as manufacturing plants and construction sites, noise levels can go up to 60 - 80 dB. While compressors operating in such set-ups might produce higher-pitched noise, they are also equipped to handle heavier workloads and provide higher air output.

Why Do Air Compressors Generate Noise?

Air compressors inherently produce noise due to various mechanical factors that come into play during operation. Some of the key reasons include:

Vibration: The mechanical movement of parts within the compressor can lead to vibrations that propagate through the structure. These vibrations contribute to the noise emitted during operation.

Friction: The interaction between moving components, such as pistons, valves, and cylinders, can create friction. Friction generates heat and sound, contributing to overall noise levels.

Air Intake and Exhaust: The air intake and exhaust processes can produce turbulent airflow and pressure changes, resulting in noise as air rushes into or exits the compressor.

Cooling Fans: Cooling fans operate to dissipate heat from air compressors during compression. These fans are loud and contribute to overall noise levels in the workplace.

How can you reduce the noise generated by an air compressor?

Reducing noise levels when operating air compressors requires a comprehensive approach encompassing careful room design, effective system management, and thoughtful selection of compressor types and maintenance practices. By implementing these strategies, businesses can not only maintain optimal performance but also create a quieter and more comfortable working environment for employees, boosting productivity and well-being.

Compressor Room Optimisation:

Positioning Within the Room: Carefully choose the location of your compressor within the dedicated compressor room. Placing the compressor away from walls and corners can prevent the reflection and amplification of noise, resulting in lower noise levels.

Floor Placement: Opt for a straight and level floor placement for the compressor. Avoid positioning it right next to walls or corners, as these configurations can amplify noise by 3 dB and 6 dB, respectively.

Sound-Absorbing Materials: When designing the compressor room, opt for sound-absorbing materials like acoustic panels and foam to reduce noise propagation. Materials like wood tend to absorb more sound compared to steel or concrete.

Location Consideration: Strategically choose the location of the compressor room. It's wise to position it away from high-traffic areas and working spaces to minimise noise exposure for employees.

Dedicated Compressor Room: Avoid installing compressors directly in the production area. Instead, invest in a dedicated compressor room, which acts as a buffer zone and contains noise within a controlled environment.

Compressed Air System Management:

Leakage Inspection: Regularly inspect your compressed air system for leaks. Leaking air not only leads to energy wastage but also contributes to noise generation. Fixing leaks can significantly reduce noise levels.

Ducting Design: Opt for appropriately sized ducting in your compressed air system. Proper sizing reduces air turbulence and noise. Additionally, consider using ducting materials that have sound-dampening properties.

Compressor Considerations:

Selecting the Type: The choice of compressor type can significantly impact noise levels. Screw compressors tend to produce less noise compared to reciprocating compressors. Similarly, oil-lubricated compressors generate less noise than oil-free compressors.

Professional Maintenance: Regular maintenance by professionals is crucial. Components like clogged filters and deteriorated oil can increase friction within the compressor, resulting in higher noise levels. Keeping the compressor in optimal condition reduces noise generation.

Single Larger Model: Instead of running multiple smaller compressors, consider replacing them with a single larger model. A larger compressor running at lower RPMs can be quieter and more efficient than multiple smaller units running at higher speeds. For example, if there is a single compressor generating 80 dB of noise level, and if another 80 dB air compressor is added, then the total noise level would be 83 dB, calculated by the following formula:

However, if there is an installation with two compressors producing 79dB of noise, then replacing those two models with one larger compressor would result in a noise reduction of 2dB resulting in 77 dB of noise.

Keep compressor noise at a minimum with ELGi’s silent air compressors.

ELGi's customer-centric focus and commitment to innovation have led to the design and manufacturing of air compressors that generate low noise and are highly efficient. ELGi's silent air compressors are designed not only for noise reduction but also for user convenience. The quieter operation ensures that the compressors can be placed closer to work areas without causing disruptions. Here are some ways ELGi’s compressed air systems can help quieter operation:

Advanced Design: ELGi’s vertically integrated manufacturing systems ensure complete control over design, and the in-house machine-building capabilities allow for the manufacturing of components with a precision finish, thus minimising noise.

Patented Technology: ELGi silent air compressors have proprietary airends that improve efficiency while generating low noise.

Isolation Technology: ELGi’s EN Series and EG Series air compressors have an encapsulated package design that acts as an acoustic enclosure that keeps the noise levels in check.

Smart Control Systems: ELGi's advanced Neuron IV controller, variable frequency drive (VFD) and the Air~Alert technology help in continuous monitoring of the compressor’s performance that optimises performance and reduces noise levels by adjusting the compressor's speed and output based on demand.

ELGi's quiet air compressors showcase advanced engineering and soundproofing technologies. By addressing noise at its source and employing various noise-reducing strategies, ELGi aims to keep compressor noise at a minimum, ultimately contributing to a quieter, more productive, and worker-friendly industrial environment.

ELGi’s Silent Air Compressors for Your Applications

Whatever your requirement, ELGi has an air compressor to match your needs. In industries where noise reduction is critical, such as manufacturing, healthcare, and laboratories, ELGi's silent air compressors create a conducive work environment. The reduced noise levels foster improved communication, better concentration, and enhanced overall well-being among employees. From smaller, low-power air compressors to powerful industrial-grade compressors, our highly skilled Channel Partners can help you find the quietest air compressor to suit your industrial requirement. In addition to offering a variety of silent air compressors, ELGi provides a wide range of pneumatic accessories that help improve the efficiency of the compressed air system and ensure application-specific air quality norms are met per the ISO 8573 standards. Contact your nearest ELGi authorised Channel Partner now and benefit from a low-noise compressed air system.