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Cost Analysis of Preventative Maintenance for Air Dryers and Filters in Compressed Air Systems: A Case Study

Robert Ruskaup

Contributed by Robert Ruskaup, Sr. Marketing Communications Specialist

July 17, 2023

This case study highlights the cost-effectiveness of implementing preventative maintenance for air dryers and filters in compressed air systems. We will focus on the potential cost savings associated with regular maintenance compared to the high expenses related to equipment replacement and downtime, including downstream components. Additionally, we will explore how partnering with Altec AIR, a leading service provider of air dryers and compressed air filters, can be beneficial in creating a comprehensive preventative maintenance program for continued success.


One of Altec AIR's Customers in the Industrial Market, is a manufacturing company that heavily relies on compressed air systems for their production processes. The Customers's compressed air system includes desiccant air dryers and both coalescing and particulate filters, which play a crucial role in maintaining clean, dry, and high-quality compressed air that their downstream equipment and processes require to function properly.

The Problem:

Our Customer faced frequent breakdowns, unexpected downtime, and high costs associated with neglecting their air dryers and filters. These issues had a significant impact on their productivity, energy consumption, and potential damage to downstream components. Recognizing the need for a proactive approach, this Customer decided to reach out to Altec AIR in order to seek advice on developing a tailored preventative maintenance program.

Preventative Maintenance Implementation with Altec AIR:

By partnering with Altec AIR, our Customer gained access to our expertise in compressed air systems and our comprehensive range of services. The implementation of the preventative maintenance program included the following key components:

  • Customized Maintenance Schedule:

    Altec AIR's Team conducted a thorough assessment of our Customer's compressed air system to determine the specific maintenance needs of their air dryers and filters. We then worked with them to develop a customized maintenance schedule to ensure that all critical components were inspected, cleaned, and serviced at appropriate intervals.

  • Calibration and Adjustments:

    Our technicians worked with the Customer to calibrate and adjust their air dryers to maintain precise dew point control, guaranteeing the delivery of dry air to downstream equipment. This optimization prevented excessive moisture accumulation and potential equipment failure.

  • Regular Inspections and Cleanings:

    Scheduled inspections were performed by the Customer's technicians to assess the condition of air dryers and filters. Any accumulated debris, contaminants, or moisture were meticulously cleaned to maintain optimal performance and prevent potential issues.

  • Filter Replacements:

    Altec AIR provided high-quality coalescing and particulate filters, which were installed at the pre-determined maintenance intervals, ensuring efficient air filtration and preventing potential blockages or equipment failures.

  • Performance Monitoring:

    Finally, our Customer implemented a comprehensive monitoring system to track the performance of their air dryers, filters, and downstream components. This allowed for early detection of any deviations or inefficiencies, enabling prompt corrective actions.

Results and Cost Analysis:

The partnership between our Customer and Altec AIR in implementing a preventative maintenance program yielded substantial benefits, leading to cost savings and operational efficiency improvements:

  • Equipment Replacement Costs:
    • Regular maintenance extended the lifespan of the air dryers and filters, significantly reducing the need for premature replacements.
    • Parts supplied by Altec AIR ensured the highest quality and compatibility, minimizing the risk of equipment failures.
  • Downtime Costs:
    • Scheduled maintenance and inspections minimized unexpected breakdowns and associated downtime.
    • Uninterrupted production resulted in increased productivity, reduced revenue loss, and improved Customer satisfaction.
  • Downstream Component Protection:
    • Well-maintained air dryers and filters prevented contaminants and moisture from reaching downstream equipment, reducing the risk of damage and costly repairs.
  • Energy Efficiency:
    • Clean and properly functioning air dryers and filters optimized compressed air quality, resulting in reduced energy consumption.
    • The prevention of excessive moisture and contaminants in the compressed air system improved the performance of downstream components, reducing energy waste.

The above case study demonstrates the cost-effectiveness of implementing preventative maintenance for air dryers and filters in compressed air systems, especially when partnering with a reputable service provider like Altec AIR. By leveraging Altec AIR's expertise and services, businesses can experience the following benefits:

  • Reduced equipment replacement costs and extended component lifespan.
  • Minimized unscheduled downtime, leading to increased production and revenue.
  • Enhanced performance and longevity of downstream components.
  • Optimized energy consumption, resulting in lower utility expenses.

Partnering with Altec AIR can help in the development of a tailored preventative maintenance program that meets specific needs, maximizes equipment reliability, and reduces long-term costs for our Customers who rely on their compressed air systems. Our expertise and comprehensive range of services create a foundation for continued success in maintaining efficient and reliable compressed air systems. Visit https://www.altecair.com to learn more about how Altec AIR can help your business achieve optimal performance and cost savings.

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