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Elgi's Two Stage Oil Free Screw Air Compressors (60-500 HP) - Pattons Inc USA

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AB Series Oil Free Screw Air Compressors 15 – 150 hp

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With the ELGi AB ‘Always Better’ series: oil-free compressed air technology that offers high performance while having minimal environmental

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How to select the right air compressor dryer for your facility

Selecting the right air compressor dryer is the key to removing damaging moisture and protecting your plant's reliability.

Moisture in compressed air systems is one of the most pervasive and expensive threats to reliability. It’s unavoidable — the air compression process produces condensation and humidity increases in the system. This leads to pipeline corrosion, product contamination and premature wear on attached tools.

An air compressor dryer protects against these threats. It removes moisture from the compressed air lines before it can cause problems. Selecting the right air compressor dryer is a critical decision that can directly impact operations and product quality.

Why dry air matters

When moisture builds up in the compressed air system, it can lead to problems like:

Rust, corrosion and scale buildup inside of pipes and air receivers.

The failure of pneumatic tools, as water washes away their lubrication.

Product contamination (for example, “fisheyes” in paint finishes, clumps in powder conveying).

Lines freezing in cold weather.

For many industries, even trace moisture can damage expensive equipment, violate safety standards and lead to product recalls.

Food and beverage : Must abide by strict hygiene standards, requiring compressed air that is free of moisture

Pharmaceutical : Ultra-dry air is essential for manufacturing and conveying sensitive drugs.

Electronics : Moisture can cause short-circuiting or corrode sensitive circuitry.

Automotive : Moisture ruins spray painting and finish work.

Manufacturing : Water can damage a variety of products.

Healthcare : Medical gas lines must be completely dry and contaminant-free to ensure patient safety.

There is more than one type of air dryer, and companies must choose which one best suits their operations

Refrigerated air dryers

Refrigerated air dryers are the most common types of dryers, and they use cooling to remove moisture. They work by cooling compressed air to a target temperature (typically 35°F to 40°F), which forces the water vapor to condense into liquid. This liquid water is then collected and removed by a condensate drain.

This method carries some advantages: They require a low initial purchase cost and they have lower operating costs than other methods. They are simple to use and easy to maintain. They provide a stable and consistent dew point that is sufficient for most industrial needs

Refrigerated dryers are the ideal choice for general manufacturing, workshops, automotive service bays and assembly plants. They are available in two main designs:

Non-cycling : The dryer’s refrigeration circuit runs constantly. This provides simple, reliable performance for facilities where air demand is high and consistent. The ELGi EGRD Series exemplifies these units,

Cycling : These energy-saving dryers are designed to adjust their cooling effort to match varying air demands. Some models use advanced controls like variable speed drive (VSD), which allows the refrigeration compressor to speed up or slow down to precisely match the cooling load in real-time. Other models, like the ELGi AR Premium Series, use thermal mass control. This method uses the refrigeration system to chill a large, dense material (the “thermal mass”). The main refrigeration circuit cycles off while the stored cold continues to chill the air, making it ideal for facilities with fluctuating air use.

Desiccant air dryers

For applications that require extremely dry air, like in food processing or pharmaceuticals, desiccant dryers are essential. A desiccant dryer passes air through a bed of highly porous desiccant media, grabbing and holding water vapor molecules to strip them from the air. This process is so effective that it can remove nearly all water vapor, enabling the dryer to achieve extremely low dew points like −40°F or −100°F.

The primary advantage of a desiccant dryer is its ability to achieve an ultra-low dew point, which is impossible for a refrigerated dryer.ELGi's HLD Series desiccant dryers are a prime example of this technology, engineered for high reliability and consistent performance in critical applications. These dryers are available in capacities from 10 CFM to 375 CFM and are designed to deliver a consistent -40°F pressure dew point. This level of performance achieves ISO 8573-1:2010 Class 2 air quality.

Key considerations

After deciding between a refrigerated or desiccant dryer, the next step is selecting the right model. This decision hinges on three key considerations: accurate sizing, the required dew point and total cost of ownership.

The most common mistake is matching the dryer's CFM rating directly to the compressor's CFM rating. A dryer advertised for "100 CFM" is rated for a specific set of ideal conditions. A facility’s actual operating conditions are rarely this perfect. On a hot summer day, for example, that same dryer's capacity to remove moisture can drop significantly. Ignoring these real-world variables or intentionally undersizing to save on initial cost will lead to moisture getting past the dryer and damaging downstream equipment.

Secondly, choose an air dryer with pressure dew point (PDP) that is at least 20°F below the lowest ambient temperature your air lines will need. If the pipes are all indoors and protected from cold, a refrigerated dryer is usually sufficient. However, if the pipes are located outdoors or in unheated areas, a desiccant dryer is required to reach a sub-zero dew point that will prevent ice from forming in the lines.

Finally, look at the total cost of ownership (TCO), not just the initial purchase price. A perfect example is comparing a non-cycling refrigerated dryer to a cycling one. The non-cycling model will have a lower initial purchase price. However, it runs at full power 100% of the time, even when air demand is low, leading to a much higher electricity bill. The cycling dryer costs more upfront, but it provides substantial energy savings by matching its power use to the air demand, often resulting in a much lower TCO over its lifetime.

Pattons is your partner

Choosing the right dryer is a critical investment in uptime. Partnering with Pattons ensures you get it right the first time. Our team eliminates the guesswork by performing a detailed system assessment to analyze your precise operating conditions, air demand and purity requirements.

Contact Pattons today to schedule your compressed air assessment and find the perfect ELGi solution for your plant.

Air Dryer comparison

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Warning signs your air compressor is trying to tell you something

Most compressor problems don’t begin as failures. They start as small changes that point to something shifting inside the system.

In a lot of facilities, compressed air systems just run. They do what they’re supposed to do, day after day, without much attention. As long as production stays on schedule and pressure seems steady, most people assume that there’s no real reason to look closer.

Until something feels off.

Maybe a warning light shows up more often than it used to. Maybe the system sounds different. Maybe pressure dips at times when it never did before. None of that feels urgent in the moment, but those are usually the first signs that the system is under more stress than it should be.

Pattons spends a lot of time helping customers sort through those moments. Not every warning means trouble, but every warning means something has changed. Knowing what to do next is what keeps small issues from turning into bigger ones.

The early signs are usually subtle

Compressors rarely fail without giving some kind of notice. More often, the system starts to behave just a little differently.

Temperatures trend higher than normal. Filters clog and restrict air flow. Dryers struggle more when humidity spikes. The compressor runs longer to keep up, even though demand hasn’t really changed. On their own, those things are easy to explain away.

Taken together, they tell a different story.

What’s usually happening is fairly straightforward. Airflow is getting restricted. Moisture is building up where it shouldn’t. Oil is breaking down faster under real operating conditions. Leaks that started small are now constant. The compressor compensates, because that’s what it’s designed to do, but that compensation comes at a cost.

The warning signs people see most often

Some issues announce themselves clearly. Others blend into the background of a busy operation. The warning signs that tend to show up again and again include:

Indicator lights or fault codes tied to temperature, pressure or service intervals

Operating temperatures creeping upward, often linked to airflow or cooling issues

Changes in sound or vibration, which usually point to developing wear

Pressure that feels less stable, even if production hasn’t stopped

Oil or moisture showing up around filters, dryers or drains.

Seeing one of these doesn’t automatically mean a compressor is on its last legs. In many cases, it means the system needs attention before things go further in the wrong direction.

When service is enough

A lot of warning signs can be resolved with straightforward service if they’re addressed early.

Replacing a clogged filter can restore airflow and reduce pressure drop. Servicing a dryer can bring moisture back under control. Fixing leaks can shorten run time and take strain off the compressor.

These aren’t dramatic fixes, but they matter. One air leak can cost upwards of $8,000+ annually!

Access to the right parts makes a big difference here. So does experience. When technicians know what they’re looking at, they’re more likely to fix the underlying issue instead of just clearing an alarm.

This is where Pattons typically gets involved. Routine maintenance, troubleshooting and parts support help customers stabilize systems before they become unreliable. When that happens, performance comes back and the compressor keeps doing its job.

When the same problems keep coming back

Sometimes, though, the same warnings don’t go away.

If a compressor keeps running hot, struggles to keep up or triggers the same faults repeatedly, that’s usually a sign that something more fundamental has changed. Production may have grown. The system may no longer be sized the way it needs to be. Repairs may be treating symptoms instead of causes.

At that point, the question shifts. It’s no longer just “How do we fix this?” but “Does it still make sense to keep fixing it?”

Those decisions are rarely clear-cut. They depend on operating conditions, service history and how much longer the equipment can realistically be expected to run reliably. An experienced service partner can help walk through those factors without pushing a one-size-fits-all answer.

Turning warnings into improvements

One of the most overlooked aspects of warning signs is that they often highlight opportunities.

A pressure issue might uncover leaks or piping restrictions that are quietly wasting energy. Fixing them can stabilize airflow and reduce power consumption. Temperature warnings often lead back to cooling or airflow problems that, once corrected, extend component life.

Moisture-related alarms frequently open the door to better dryer performance and cleaner air. In some facilities, that directly improves product quality or reduces downstream maintenance. Instead of clearing alarms and moving on, these moments can be used to make systems run better than they did before.

Paying attention pays off

Compressed air systems communicate all the time. Facilities that listen tend to avoid surprises.

That doesn’t mean reacting to every alert as an emergency. It means taking changes seriously, staying on top of maintenance and working with partners who understand how systems behave over time.

Pattons helps customers interpret warning signs, supply the right parts and provide service that keeps systems running reliably as conditions change.

Is your air compressor trying to tell you something? Learn to spot the early warning signs of system stress, from rising temperatures to fre

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Five trends shaping industrial compressed air in 2026

The era of treating compressed air as invisible infrastructure is ending. The facilities that will thrive in the coming year are those that recognize compressed air as a strategic lever.

Compressed air has long been the backbone of manufacturing. It is essential and reliable, but often overlooked until something goes wrong. As we enter 2026, the conversation around compressed air is shifting from simple utility to strategic asset.

We are entering a new era defined by rising energy costs and the urgent need for operational efficiency. With compressed air systems accounting for up to 40% of industrial energy costs, the old approach of "set it and forget it" is no longer a viable business strategy.

For decision-makers navigating this new reality, understanding the technological shifts is crucial. These are the five key trends that will define industrial efficiency in 2026.

The VFD is becoming essential

While variable frequency drive (VFD) technology isn’t new, 2026 marks the inflection point where it becomes the industrial standard.

The math is simply too compelling to ignore. VFD compressors now consistently deliver 30%-35% energy savings by matching motor speed to actual air demand in real-time. For a facility running multiple shifts with varying demand, a single VFD unit can do the work that previously required multiple fixed-speed machines. Aside from saving electricity, VFD units also reduce mechanical stress, lowering peak demand charges and securing a payback period that often ranges from just two to five years.

ELGi has integrated advanced VFD technology directly into its rotary screw compressors, including the EG Series and EN Series, pairing them with the intelligent Neuron 4 controller. This combination enables the compressor to modulate speed with extreme precision, maintaining consistent pressure, without the wasteful load-unload cycles of other systems. Whether it’s for a small shop or a medium to large industrial plant, ELGi’s VFD options ensure facilities only pay for the air they actually use.

Utilize waste heat recovery

The thermodynamics of compression present a massive opportunity. Nearly 96% of the electrical energy used by a compressor is converted into heat. Historically, we vented this into the atmosphere. Today, we capture it.

Modern heat recovery systems allow manufacturers to recapture 72%-80% of this thermal energy for productive use. This energy can be used to heat warehouse spaces, generate hot water or pre-heat industrial processes.

ELGi’s heat recovery systems have achieved up to 96% energy capture in specific applications. This transforms your compressor from a pure energy consumer into a dual-purpose asset that lowers your heating bills and contributes directly to decarbonization goals.

Leak detection is no longer guesswork

While we love discussing new machinery, the fastest return on investment often comes from optimizing what you already have. Leaks typically waste 20%-30% of compressor output.

The industry standard is moving toward ultrasonic leak detection tuned to 40 kHz. This technology enables technicians to identify leak locations with precision, even in noisy industrial environments. Rather than relying on audible hissing, these instruments detect the turbulence of escaping air and tag leaks with data regarding decibel levels and estimated cost.

In 2026, the trend is shifting from occasional, outsourced checks to continuous, data-driven monitoring. Forward-thinking facilities are now integrating acoustic imaging into their standard predictive maintenance (PdM) schedules. By visualizing leaks on digital screens and quantifying the exact dollar value of air loss in real-time, plant managers can create a prioritized roadmap for repair. This ensures maintenance hours are spent exactly where they generate the highest return.

From components to integrated systems

A significant philosophical shift in 2026 is the move away from buying "a compressor" to designing "an air system."

Buying a larger machine without accounting for piping, storage or air treatment is a recipe for inefficiency. Customers are increasingly choosing system-level optimization. This means integrated designs where master controllers balance loads across multiple units to maintain peak efficiency. It involves implementing bundled solutions — like integrating the compressor, dryer and receiver tank — to eliminate pressure drops and connection points.

At Pattons, our application engineers help customers model proposed changes before implementation. We evaluate piping architecture, storage capacity and flow dynamics to design a holistic system. By sequencing your compressors correctly and optimizing storage, we often find that facilities can meet demand with smaller, more efficient equipment than they originally thought necessary.

Oil-free technology expands beyond food and pharmaceutical

Historically, oil-free compressors most popular in the food and beverage, and pharmaceutical sectors. However, the rapid expansions of microchip production, EV battery production and printed circuit board (PCB) manufacturing are now the primary engine driving oil-free adoption.

As electronics become smaller and more sophisticated, they are less tolerant to oil contamination. In these high-precision environments, even microscopic traces of oil vapor can disrupt delicate coatings, degrade battery electrolytes or cause short circuits in microscopic components. Conventional filtration often struggles to guarantee the absolute purity required for these nanometer-scale operations.

Manufacturers are increasingly specifying Class 0 oil-free air to eliminate the risk of product defects entirely, ensuring that the compressed air does not become a bottleneck in quality in high-tech production.

The path forward

Navigating the technological shifts of 2026 demands a strategic partnership. As a dedicated distributor, Pattons operates at the intersection of manufacturer innovation and practical application. Our role extends beyond supplying ELGi’s advanced hardware. We engineer the ecosystem that enables it to thrive in your facility.

Our team bridges the gap between global innovation and the production floor. We translate broad industry trends, ranging from VFD efficiency to oil-free purity, into a tailored roadmap for a business. This might involve modeling the ROI of a heat recovery system or conducting a comprehensive audit to pinpoint energy waste.

Treating compressed air as a hidden cost center is a missed opportunity. The technology to transform operations is available now. Contact Pattons today for a comprehensive system assessment.

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How to navigate food-grade oil and filtration for compressed air safety

Food and beverage manufacturers can secure their air supply by selecting the right combination of high-quality lubricants and air filtration, or by opting for oil-free technology. Making this critical choice ensures compliance while protecting brand reputation and consumer health.

In food and beverage operations, compressed air touches nearly every stage of production. It powers pneumatic control systems, drives packaging lines, assists in cooling and freezing processes, cleans containers and comes into direct contact with food products.

Crucially, compressed air that is not treated is far from clean. Contaminants can enter the system through compressor lubricants, mechanical wear, storage vessels and distribution piping. In a food manufacturing environment, any point where compressed air contacts products or machines is a contamination risk.

Excess oil in a compressed air system can create breeding grounds for microorganisms. This can damage equipment and force facility shutdowns. More importantly, it can spoil products and create food safety hazards. With consumer health and brand reputation on the line, the stakes are simply too high for food and beverage manufacturers to neglect air purity.

To mitigate these risks, manufacturers must select the right compressed air technology. This means choosing between oil-free air compressors or oil-flooded compressors that use food-grade oil.

Understanding food-grade oil

When oil-lubricated compressors are used, the type of lubricant matters enormously. NSF International, an independent third-party organization, classifies food-grade lubricants into distinct categories that dictate how and where they can be used.

NSF H1 lubricants are what most industry professionals refer to as "food-grade oil." They are formulated to be tasteless, odorless and physiologically harmless. H1 formulations contain base stocks, additives and thickeners approved by the FDA. However, strict limits remain — if contact with food occurs, the contamination must not exceed 10 parts per million, or the product is deemed unsafe for consumption. IS THERE AN ELGI ONE?

In contrast, H2 lubricants can be used within food processing facilities, but exclusively in areas where there is absolutely no possibility of food contact. While they do not need to meet the same strict purity bar as H1 lubricants, they cannot contain carcinogens, mutagens, teratogens or intentionally added heavy metals like lead, mercury or arsenic.

For air compressors operating in these environments, using an NSF H1 registered lubricant is the minimum standard if there is any possibility of air-to-food contact. ELGi offers food-grade synthetic lubricant options, such as Airlube Food Grade, specifically formulated for use in its EG and EN Series oil-lubricated air compressors.

The necessity of multi-stage filtration

While NSF H1 lubricants are formulated to be safe for operations, they are not intended to be food ingredients. Furthermore, the compression process concentrates atmospheric contaminants, like dust and moisture, that must be removed in addition to filtering the lubricant.

To achieve the high purity levels required for food safety, food and beverage manufacturers need to employ multi-stage filtration. This approach arranges filters to target different types and sizes of contaminants. A typical system includes three distinct stages:

Stage 1: General purpose filter: The first line of defense removes bulk liquid water, rust and large particulates (typically down to 1 micron). This protects the finer filters downstream from becoming clogged too quickly.

Stage 2: Coalescing filter: This forces small oil aerosols and fine water mists to merge, or “coalesce,” into larger droplets that are then drained away. This stage is essential for reducing oil content to acceptable levels.

Stage 3: Final/sterile particulate: An ultra fine particulate or sterile filter (often 0.01 micron) captures sub micron particles and microorganisms at the point of use, giving “food grade” or “sterile” air suitable for direct or high risk contact.

With any oil-flooded system there is always a risk of contamination. For the most part, there is no feasible way to detect oil leaking into the air in real time. A facility often does not discover the issue until the damage has already occurred.

Consider oil-free solutions

Oil-free compressors eliminate the risk of oil contamination completely. Because there is no oil used in the compression process, the air stream remains free of oil aerosols and vapor. This simplifies downstream filtration requirements. It also reduces maintenance costs by eliminating oil filters and condensate separators. Oil-free compressors provides the most reliable path to ISO 8573-1 Class 0 certification.

ELGi's AB Series oil-free screw air compressors are designed for these sensitive applications. They deliver Class 0 certified oil-free air and are built with FDA-approved materials. They also feature a compact footprint with lower operating noise, as well as an industry-leading 5-year airend and package warranty.

For applications demanding higher capacities and maximum uptime, ELGi’s OF Series two stage oil free air compressors offer several distinct benefits. They feature an exclusive eta-V rotor design for peak efficiency and food-grade PTFE-coated airends that resist corrosion and extreme heat. Maintenance is drastically reduced by a capacity control system built to run for over a million cycles with zero upkeep.

Ensuring food safety with Pattons

Whether designing a new facility from the ground up or retrofitting an existing plant, achieving food safety compliance requires more than just buying the right compressor. It demands a holistic approach to system design, piping, filtration and ongoing maintenance.

At Pattons, we specialize in helping food and beverage manufacturers navigate these complexities. For existing facilities, we offer audits to identify contamination risks, moisture issues and inefficiencies in the current setup. For new builds, we provide end-to-end system design that integrates the optimal mix of compression technology and multi-stage filtration to ensure safety from day one.

Don't leave food safety to chance. Contact us today for a consultation to ensure your compressed air system is safe, efficient and fully compliant.

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Pattons offers efficient and reliable oil-free screw air compressors that generates pure and high quality compressed air.

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Why financing an air compressor makes smart sense

Investing in a new air compressor or compressed air system can overhaul production, improve product quality, boost efficiency and safeguard reliability. Financing options makes it easier to plan and budget.

Air compressors and their systems are typically long-term investments for manufacturers and industrial facilities, with most looking at a decade of operation. With so many production processes reliant on compressed air, it’s considered a “fourth utility.” Air compressors operate in an ecosystem, though, and their usage also contributes to as much as 30% of a company’s energy costs. Ensuring system efficiency and securing modern equipment via financing helps minimize those costs and maximize ROI.

It’s important to think of air compression systems as key components in energy efficiency, product quality and reliable operations. With an upgraded system, a business can lower its energy consumption and reduce its utility costs. A new system is more reliable, so breakdowns and maintenance are reduced. Cleaner air can help tools perform at their peak and improve product quality — especially in industries like food and beverage, pharmaceuticals and manufacturing.

Upgrades always come with budget considerations, though, and a new compressed air system can be a significant capital expense. Financing protects cash flow while enabling access to better- performing, more energy-efficient systems. It’s a strategic way to move forward without dipping into operating capital or credit lines, and monthly payments make it easier to budget for essential upgrades.

Pattons provides financing for companies that align with their unique business needs. This means adapting to a company’s project timelines, seasonal cash flows and other factors that affect operations. Options like 0% interest and no payment for 90 days make financing accessible to all businesses, giving them the opportunity to upgrade when they need it most.

Betting on bigger

For companies upgrading to larger systems, the increased capacity can enable production to scale. This can future-proof the business for growing demand or help it ramp up production to meet deadlines. Many companies will see dramatic transformations when they no longer are held back by aging systems that break down or require significant maintenance.

Financing with Pattons helps companies act sooner. Instead of making a big capital outlay, it enables them to spread the cost over time while still getting the reliability and efficiency they need right now.

A bigger system could include new air compressors, piping, filters, dryers or more, depending on the operation. Pattons works with businesses to size and spec the right solution. It provides complete turnkey system delivery — including installation, piping, and remote monitoring — to ensure smooth transitions with minimal disruption.

Pattons can finance almost any part of a compressed air system, even the installation itself. When paired with a professional air audit, financing can help prioritize the upgrades that deliver the fastest return on investment.

Financing can include:

Air compressors

Filtration and piping

Dryers, chillers and blowers

System master controllers

Remote monitoring

Receiver tanks

Vacuum pumps

Medical air and vacuum

Installation and more

Pattons partners with LEAF to offer equipment financing at interest rates lower than the national mortgage index. It has no impact on a company’s current credit lines. Explore our LEAF financing options.

The cost of inaction

Delaying necessary upgrades always comes at a cost, and that is usually measured in energy usage, repairs, product quality and overall downtime. Waiting too long may even cost more than acting early.

The U.S. Department of Energy has reported that 20% – 30% of compressed air around the country is being wasted through leaks. Water and oil contamination cause damage to products and shut down production. Production delays cause companies to lose customers.

Financing helps companies to avoid these risks, particularly when their current air compression systems are aging or faltering. It eliminates these challenges and provides an opportunity for companies to reduce operating costs and improve operations.

Learn how air compressor financing helps manufacturers upgrade compressed air systems, reduce energy costs, improve reliability and boost pr

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The road to long-term compressor reliability

Moving from reactive maintenance to complete preparedness is about finding the right balance between proactive planning and rapid, local response with a true partner.

Compressed air systems are the lifeblood of manufacturing facilities, powering everything from the production line to handheld pneumatic tools. This means system reliability is non-negotiable. But a durable system—one that performs when it counts— doesn’t just come from buying the right equipment. Success is built over time, through a smart, proactive maintenance and support strategy.

Long-term results require long-term thinking. A modern compressed air system is designed to last for a decade or more, but only with the right care. Preventive maintenance is what protects that investment, dramatically reducing the risk of costly downtime and unexpected failures. The most effective way to implement this is to work with an expert partner. For manufacturers in the Southeast, that means building a relationship with a local partner like Pattons.

Rather than simply supplying parts, Pattons stays invested for the full life of the equipment. This means ensuring the right components are always in stock, deploying expert technicians when needed and actively helping customers strategize their preventive maintenance to keep operations running smoothly.

Proactive planning

It’s not only about responding if there’s an issue. A local partner’s true value is their ability to provide complete preparedness, and that begins long before a service call is placed. This strategic foundation for reliability involves working alongside facility managers to design a maintenance and support program tailored to their unique operational needs.

The program often begins with a proactive air audit, to pinpoint leaks, inefficient usage and improper pressure settings which can identify significant, immediate energy savings. More critically, the audit serves as a long-term diagnostic tool. It uncovers potential points of failure before they can cause an unexpected shutdown, providing a data-driven roadmap for system optimization and maintenance.

The insights from an air audit allow for the creation of a customized maintenance agreement with a concrete plan that aligns with specific production cycles, equipment and budget goals. By scheduling and handling routine service proactively, from filter changes to oil analysis, small issues are addressed before they can escalate into something more serious. This approach transforms maintenance from a reactive necessity into a strategic advantage.

In addition, a truly robust strategy must include comprehensive redundancy planning, to answer the critical question: "What happens if a primary compressor fails?" A thorough assessment of an operation's most critical needs forms the basis of an effective backup plan. This could involve installing a backup compressor onsite for immediate switchover or establishing a clear protocol for the rapid deployment of rental units. The ultimate goal is to ensure that a single component failure doesn't bring an entire operation to a standstill.

When the clock is ticking

Even the best-maintained systems face unexpected events, from storms and power surges to simple component failure. In compressed air systems, common failure points like pumps, belts, dryers or control panels can bring production to a halt. According to a Siemens 2024 industry report, a single hour of unplanned downtime can cost anywhere from $150,000 for smaller operations to over $2.3 million in sectors like automotive. When this happens, response time becomes crucial.

Pattons focuses on a rapid part replacement service to help facilities mitigate this challenge. Pattons maintains local warehouses stocked with critical parts and employs local, factory-trained technicians. This proximity to the customer ensures the fastest possible response. It's a strategy designed to eliminate the costly delays of cross-country shipping or long-distance travel, with the goal of getting an expert and the right part to a facility ASAP.

But speed is only half the battle – scale matters too. Most facilities simply can't afford to stock backups for every critical component. But Pattons maintains a robust parts stock for all major brands, not just the ELGi systems we distribute. This includes parts for competing OEMs to ensure production continuity for our customers.

The Pattons partnership

True preparedness extends beyond maintenance schedules and emergency calls; it is built on a partnership that is fully invested in a facility's operational success. As a dedicated local partner, Pattons provides the tools and expertise needed to keep systems performing at their best. This includes:

Access to Technical Expertise: Pattons provides direct access to factory-trained technicians, who serve as a critical resource for troubleshooting complex issues and advising strategic system upgrades.

A Focus on System Optimization: The relationship moves beyond reactive repairs to proactive system enhancement. Pattons actively identifies opportunities to improve a system’s efficiency, reduce long-term energy costs, and extend the equipment’s operational life.

A Commitment to Operational Success: The engagement is rooted in a commitment to the facility’s success. By simplifying procurement with streamlined processes and offering clear, actionable advice, Pattons builds a foundation of trust and reliability.

Ultimately, the goal is to make system reliability straightforward. By ensuring the right parts are shipped quickly and backing them with expertise that solves real-world challenges, Pattons establishes and earns a partnership built on trust every single day.

Explore Pattons' parts and service offerings to plot your roadmap to true system resilience: https://www.pattonsinc.com/multi-brand-parts/

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How to select the right air compressor dryer for your facility

Selecting the right air compressor dryer is the key to removing damaging moisture and protecting your plant's reliability.

Moisture in compressed air systems is one of the most pervasive and expensive threats to reliability. It’s unavoidable — the air compression process produces condensation and humidity increases in the system. This leads to pipeline corrosion, product contamination and premature wear on attached tools.

An air compressor dryer protects against these threats. It removes moisture from the compressed air lines before it can cause problems. Selecting the right air compressor dryer is a critical decision that can directly impact operations and product quality.

Why dry air matters

When moisture builds up in the compressed air system, it can lead to problems like:

Rust, corrosion and scale buildup inside of pipes and air receivers.

The failure of pneumatic tools, as water washes away their lubrication.

Product contamination (for example, “fisheyes” in paint finishes, clumps in powder conveying).

Lines freezing in cold weather.

For many industries, even trace moisture can damage expensive equipment, violate safety standards and lead to product recalls.

Food and beverage : Must abide by strict hygiene standards, requiring compressed air that is free of moisture

Pharmaceutical : Ultra-dry air is essential for manufacturing and conveying sensitive drugs.

Electronics : Moisture can cause short-circuiting or corrode sensitive circuitry.

Automotive : Moisture ruins spray painting and finish work.

Manufacturing : Water can damage a variety of products.

Healthcare : Medical gas lines must be completely dry and contaminant-free to ensure patient safety.

There is more than one type of air dryer, and companies must choose which one best suits their operations

Refrigerated air dryers

Refrigerated air dryers are the most common types of dryers, and they use cooling to remove moisture. They work by cooling compressed air to a target temperature (typically 35°F to 40°F), which forces the water vapor to condense into liquid. This liquid water is then collected and removed by a condensate drain.

This method carries some advantages: They require a low initial purchase cost and they have lower operating costs than other methods. They are simple to use and easy to maintain. They provide a stable and consistent dew point that is sufficient for most industrial needs

Refrigerated dryers are the ideal choice for general manufacturing, workshops, automotive service bays and assembly plants. They are available in two main designs:

Non-cycling : The dryer’s refrigeration circuit runs constantly. This provides simple, reliable performance for facilities where air demand is high and consistent. The ELGi EGRD Series exemplifies these units,

Cycling : These energy-saving dryers are designed to adjust their cooling effort to match varying air demands. Some models use advanced controls like variable speed drive (VSD), which allows the refrigeration compressor to speed up or slow down to precisely match the cooling load in real-time. Other models, like the ELGi AR Premium Series, use thermal mass control. This method uses the refrigeration system to chill a large, dense material (the “thermal mass”). The main refrigeration circuit cycles off while the stored cold continues to chill the air, making it ideal for facilities with fluctuating air use.

Desiccant air dryers

For applications that require extremely dry air, like in food processing or pharmaceuticals, desiccant dryers are essential. A desiccant dryer passes air through a bed of highly porous desiccant media, grabbing and holding water vapor molecules to strip them from the air. This process is so effective that it can remove nearly all water vapor, enabling the dryer to achieve extremely low dew points like −40°F or −100°F.

The primary advantage of a desiccant dryer is its ability to achieve an ultra-low dew point, which is impossible for a refrigerated dryer.ELGi's HLD Series desiccant dryers are a prime example of this technology, engineered for high reliability and consistent performance in critical applications. These dryers are available in capacities from 10 CFM to 375 CFM and are designed to deliver a consistent -40°F pressure dew point. This level of performance achieves ISO 8573-1:2010 Class 2 air quality.

Key considerations

After deciding between a refrigerated or desiccant dryer, the next step is selecting the right model. This decision hinges on three key considerations: accurate sizing, the required dew point and total cost of ownership.

The most common mistake is matching the dryer's CFM rating directly to the compressor's CFM rating. A dryer advertised for "100 CFM" is rated for a specific set of ideal conditions. A facility’s actual operating conditions are rarely this perfect. On a hot summer day, for example, that same dryer's capacity to remove moisture can drop significantly. Ignoring these real-world variables or intentionally undersizing to save on initial cost will lead to moisture getting past the dryer and damaging downstream equipment.

Secondly, choose an air dryer with pressure dew point (PDP) that is at least 20°F below the lowest ambient temperature your air lines will need. If the pipes are all indoors and protected from cold, a refrigerated dryer is usually sufficient. However, if the pipes are located outdoors or in unheated areas, a desiccant dryer is required to reach a sub-zero dew point that will prevent ice from forming in the lines.

Finally, look at the total cost of ownership (TCO), not just the initial purchase price. A perfect example is comparing a non-cycling refrigerated dryer to a cycling one. The non-cycling model will have a lower initial purchase price. However, it runs at full power 100% of the time, even when air demand is low, leading to a much higher electricity bill. The cycling dryer costs more upfront, but it provides substantial energy savings by matching its power use to the air demand, often resulting in a much lower TCO over its lifetime.

Pattons is your partner

Choosing the right dryer is a critical investment in uptime. Partnering with Pattons ensures you get it right the first time. Our team eliminates the guesswork by performing a detailed system assessment to analyze your precise operating conditions, air demand and purity requirements.

Contact Pattons today to schedule your compressed air assessment and find the perfect ELGi solution for your plant.

Air Dryer comparison

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Warning signs your air compressor is trying to tell you something

Most compressor problems don’t begin as failures. They start as small changes that point to something shifting inside the system.

In a lot of facilities, compressed air systems just run. They do what they’re supposed to do, day after day, without much attention. As long as production stays on schedule and pressure seems steady, most people assume that there’s no real reason to look closer.

Until something feels off.

Maybe a warning light shows up more often than it used to. Maybe the system sounds different. Maybe pressure dips at times when it never did before. None of that feels urgent in the moment, but those are usually the first signs that the system is under more stress than it should be.

Pattons spends a lot of time helping customers sort through those moments. Not every warning means trouble, but every warning means something has changed. Knowing what to do next is what keeps small issues from turning into bigger ones.

The early signs are usually subtle

Compressors rarely fail without giving some kind of notice. More often, the system starts to behave just a little differently.

Temperatures trend higher than normal. Filters clog and restrict air flow. Dryers struggle more when humidity spikes. The compressor runs longer to keep up, even though demand hasn’t really changed. On their own, those things are easy to explain away.

Taken together, they tell a different story.

What’s usually happening is fairly straightforward. Airflow is getting restricted. Moisture is building up where it shouldn’t. Oil is breaking down faster under real operating conditions. Leaks that started small are now constant. The compressor compensates, because that’s what it’s designed to do, but that compensation comes at a cost.

The warning signs people see most often

Some issues announce themselves clearly. Others blend into the background of a busy operation. The warning signs that tend to show up again and again include:

Indicator lights or fault codes tied to temperature, pressure or service intervals

Operating temperatures creeping upward, often linked to airflow or cooling issues

Changes in sound or vibration, which usually point to developing wear

Pressure that feels less stable, even if production hasn’t stopped

Oil or moisture showing up around filters, dryers or drains.

Seeing one of these doesn’t automatically mean a compressor is on its last legs. In many cases, it means the system needs attention before things go further in the wrong direction.

When service is enough

A lot of warning signs can be resolved with straightforward service if they’re addressed early.

Replacing a clogged filter can restore airflow and reduce pressure drop. Servicing a dryer can bring moisture back under control. Fixing leaks can shorten run time and take strain off the compressor.

These aren’t dramatic fixes, but they matter. One air leak can cost upwards of $8,000+ annually!

Access to the right parts makes a big difference here. So does experience. When technicians know what they’re looking at, they’re more likely to fix the underlying issue instead of just clearing an alarm.

This is where Pattons typically gets involved. Routine maintenance, troubleshooting and parts support help customers stabilize systems before they become unreliable. When that happens, performance comes back and the compressor keeps doing its job.

When the same problems keep coming back

Sometimes, though, the same warnings don’t go away.

If a compressor keeps running hot, struggles to keep up or triggers the same faults repeatedly, that’s usually a sign that something more fundamental has changed. Production may have grown. The system may no longer be sized the way it needs to be. Repairs may be treating symptoms instead of causes.

At that point, the question shifts. It’s no longer just “How do we fix this?” but “Does it still make sense to keep fixing it?”

Those decisions are rarely clear-cut. They depend on operating conditions, service history and how much longer the equipment can realistically be expected to run reliably. An experienced service partner can help walk through those factors without pushing a one-size-fits-all answer.

Turning warnings into improvements

One of the most overlooked aspects of warning signs is that they often highlight opportunities.

A pressure issue might uncover leaks or piping restrictions that are quietly wasting energy. Fixing them can stabilize airflow and reduce power consumption. Temperature warnings often lead back to cooling or airflow problems that, once corrected, extend component life.

Moisture-related alarms frequently open the door to better dryer performance and cleaner air. In some facilities, that directly improves product quality or reduces downstream maintenance. Instead of clearing alarms and moving on, these moments can be used to make systems run better than they did before.

Paying attention pays off

Compressed air systems communicate all the time. Facilities that listen tend to avoid surprises.

That doesn’t mean reacting to every alert as an emergency. It means taking changes seriously, staying on top of maintenance and working with partners who understand how systems behave over time.

Pattons helps customers interpret warning signs, supply the right parts and provide service that keeps systems running reliably as conditions change.

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RECIPROCATING AIR COMPRESSORS

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Pattons provide reciprocating air compressors that are built to provide innovative solutions to meet all your compressor needs. Explore prod