Compressed air and metalwork
Compressed air is vital in nearly all aspects of metal products manufacturing. Machining, fabricating, and metal casting operations use air in many ways. Steady pressure and clean, dry air are critical for all CNC systems, from laser and plasma cutting to precision multi-axis grinding. They are equally important for coating and paint spraying processes.
Grinders and other pneumatic hand tools typically consume a lot of air, and when multiple tools are in use, inadequate flows (perceived as low pressure) can slow fabricators down. Adding in high intermittent demands from sand, soda or shot blasting makes achieving a reliable, energy-efficient air supply even more challenging.
Kaeser understands these challenges and has helped countless metal products manufacturers maintain efficiency production with minimal downtime.
CNC machines and automation
Modern production machinery is designed to operate under specific conditions, and many systems include sensors/safety features to make sure they are getting proper inputs needed to achieve peak output. Pressure fluctuations outside of spec can cause shutdowns, slowing production and producing scrap. Likewise, low air quality from moisture, dirt, dust, or oily air can cause equipment malfunction and downtime. This is also very true for robotics, conveying systems, and other automation.
Laser and plasma cutting
High pressure system for laser cutting
Compressed air has become increasingly accepted as an effective and cost saving alternative to nitrogen and oxygen as an assist gas for plasma and laser cutters, and a number of OEMs supply or recommend Kaeser compressors for their CO2 /fiber laser and plasma cutters. For some customers, the 217 psig max pressure on our screw compressors meets their needs. Others opt to add high pressure boosters. Kaeser also builds fully integrated skids for air-assist. For those who rely on nitrogen, Kaeser is a popular choice to feed onsite nitrogen generation.
Metal casting
With their combination of high heat and insidious airborne particulate, foundries are notoriously bad environments for compressors. Kaeser’s full cabinet and smart airflow design helps keep out contaminants for longer, more reliable operation. And generously sized coolers keep our units going when others can no longer take the heat. But sometimes, even that is not enough. Kaeser’s custom engineering capabilities offer different approaches to dealing with poor compressor room conditions
Air knives
Air knives rely on steady streams of compressed air for removing cutting fluid or other solutions from metal products. This is often a very wasteful use of air, but with a combination of smart system design and efficient, purpose-built nozzles you can cut the energy consumption. In some cases, it may make sense to use blowers instead of compressors for air knives. Kaeser can help there, too.
Whether you are cutting, bending, rolling, blasting, grinding, milling, or painting, Kaeser has the products and expertise to provide the optimal mix of pressure, flow, and air quality to your plant. We have a proven track record of increasing productivity by reducing maintenance, downtime, scrap and energy consumption.
Kaeser compressed air products for the metal fabrication industry
Rotary screw compressors
Kaeser’s rotary screw compressors with the world renowned Sigma Profile™ airend offer the best in rugged reliably and superior efficiency. Available from 3 to 700 hp, these packages are designed for ease of maintenance, deliver ultra-low noise levels, and consistently are more efficient than the competition.
Compressed air treatment products
Dirt, oil, and other impurities enter the compressor with atmospheric air and during the compression process. If not removed, these contaminants may cause costly production problems including equipment contamination and accelerated tool wear. Kaeser offers a complete line of air treatment products including dryers, filters, and drains to prepare compressed air for even the most stringent requirements
Compressed air piping
Kaeser's SmartPipe™ is a modular aluminum pipe for compressed air installations, offering both lower installation costs and lower long-term operating costs. From small shops to large industrial systems, SmartPipe is great for all facilities and is available in sizes up to 8" pipe diameter.
Master controllers
The SIGMA AIR MANAGER 4.0 compressed air management system monitors and controls all components within the compressed air supply system achieving maximum cost savings.
- Improved pressure stability and automatic matching of delivery according to fluctuating demand
- Continuous fine-tuning of system performance to ensure optimized energy efficiency
- Predictive Maintenance by Kaeser specialists prevents unplanned downtime.