Compressors can be a hidden source of contaminants in food production facilities. Libby Peacock, compressed air expert at Rubix at Rubix explains how good maintenance can reduce this risk – and save businesses money.

Compressed air is a vital component for many manufacturing processes and is widely used across food production. However, compressors can create contaminants if you do not correctly operate and maintain them. In this article, we will unpack the ISO standards for compressed air used in food manufacturing – and demonstrate how being proactive can be much more cost-effective than dealing with issues after they arise.

Understanding ISO standards

Before addressing an issue, we must fully understand it. The ISO standards for compressed air in food production are complex, but can be broken down as follows:

ISO 12500-1-2007 is for classifying filters for compressed air. It also specifies the processes required for testing the coalescing filters used in compressed air systems to determine their effectiveness in removing oil aerosols.

ISO 8573-1-:2010 specifies the purity levels required for compressed air in terms of solid particles, humidity and liquid water, and oil. The cleanest and purest air is classified as Class 1,1,1. It is important to be aware that the specific air grade required by the standard depends on the application, therefore the type of ISO 12500-1:2007 filter needed will vary accordingly.

Moisture monitoring

The food industry relies on maintaining excellent environmental conditions to ensure product quality and safety. This includes a strong focus on humidity by monitoring the dew point – the temperature at which condensation forms in the air.

Fail to prevent this and you will experience moisture-related problems such as product quality issues; for example, clumping of powdered ingredients. It can also impact efficiency and energy consumption as moisture can extend processing times. More importantly, it can lead to mould growth which is a serious safety issue.

Compressors use atmospheric air to generate compressed air, and this air can contain pollutants. Contaminants such as moisture, solid particles and oil can still enter the system after the drying process.  Therefore, it’s crucial to install point-of-use filters that comply with ISO standards for food-grade air, especially in applications where compressed air is used directly in the manufacturing process. These filters are specifically designed to produce food-grade air by using fine filter elements.

At Rubix, we advise our customers to install these filters on an application-by-application basis. This is because going overboard with filtration can lead to unnecessary energy consumption due to pressure drops in the system.

Remain vigilant

Even with primary compressor filters and a dryer that produces air with a dew point of -40°C, compressors can still create contaminants. Furthermore, contaminants can also occur after the filtration and drying process. The first point of order should be checking and replacing the point-of-use filter elements to ensure they remain effective. Blocked filters can also cause pressure drops, again placing extra load on the compressor, which increases your energy costs and carbon emissions.

Additional areas on which you should focus include grease from pneumatic components, as this lubricant can seep out to contaminate food products. Another area often overlooked is rubber seals. Typically found in components like cylinders and valves, these seals can swell and degrade over time, introducing particles into the compressed air system. Also, remain vigilant to the threat of rust, which can form in pipes before travelling through the compressed air supply.

Other risks to monitor closely include drain failures. A mechanical auto drain can get stuck or simply stop operating, while human error can lead to manual drains not being emptied regularly. Both instances can introduce unwanted moisture and contaminants. Similarly, an unsealed system is an open door for atmospheric contamination. To help prevent this, businesses should install silencers in all valve exhausts.

Proactive maintenance

As with other areas of food production, proactive maintenance can deliver a superb return on investment, and spending a little on service, maintenance and repair can prevent a large-scale problem with food contamination.

Rubix recommends several steps for best practice in compressor maintenance:

Firstly, regularly change point-of-use filter elements as part of your planned maintenance schedule. Secondly, monitor and maintain filter drains – automatic or manual – to prevent moisture ingress. Thirdly, ensure that all components are correctly sealed to prevent atmospheric contaminants from entering the compressed air system.

By implementing these guidelines to maintain high air quality standards, food manufacturing plants can ensure the safety and quality of their products. This also helps to retain and enhance customer trust and brand loyalty while also avoiding costly recalls.

Ask for help

If you are not sure where to start with addressing the risks of air contamination from compressors, talk to the experts. The unique size and scale of Rubix means that we are well positioned to help you devise and implement a plan, whether that is across multiple European sites or just one food production facility. Rubix is the only company in this space with a pan-European footprint, carrying all premium brands. The food industry is our primary focus, and we have decades of in-house experience in compressed air for these applications.

For further information or to get in touch, visit https://uk.rubix.com/en/news/food_grade_air_treatment_guide.