Repair vs. replace compressed air system: Pros and cons

How do you know when it’s time to replace a compressed air system, or if it’s more cost-effective to continue repairing it? A quick repair may save time and money. But, when those quick repairs happen more and more often, it starts to seem like you’re throwing good money after bad. At what point is it worth making the larger investment in a new system? 

There are a number of pros and cons to consider when you’re deciding whether to repair vs. replace a compressed air system. And cost is only one part of the equation: There’s also energy efficiency, reliability, and the overall user experience along with capital expense and ROI.

By fully understanding each option, you can make the best choices that align with your financial constraints, operational requirements, and long-term goals.

In this article, we’ll explore the benefits and drawbacks of replacing or repairing your system. You’ll also learn how to consider various factors as they relate to your unique situation. 

When to consider air compressor replacement vs repair

Before we get into the specifics, it’s important to note that you should consider air compressor replacement vs. repair proactively. That is, before a problem arises. 

A broken compressor can halt production, which can mean losing up to $200 a minute in lost productivity. That’s not the best time to make a comprehensive, informed decision about whether to invest in a new system or repair what you have. 

Instead, use the points here to take stock of your equipment now. You can also consider ways to reduce wear and tear and prevent breakdowns. These steps will help you make the best decision when it’s time to choose between repairs or replacement. 

Air compressor repairs

Here are the pros and cons of repairing a broken air compressor:

Pros

• Cost-effective, immediate solution: Repairs often cost a fraction of what a new unit would. That’s especially so when you proactively address minor issues or normal wear and tear. And, the savings are immediate – your system could be back up and running in less than a day. 
• Extending the equipment's life: A well-executed repair can breathe new life into your compressed air system, potentially adding years to its serviceable life. This postpones the need for capital expenditure on a new unit. Each year you go without purchasing a new system increases the ROI on your current unit. 

Cons

• Maintenance costs can add up: While individual repairs might be cheaper, the cost of repairing frequent breakdowns adds up over time. That includes any parts you purchase plus the time your maintenance team takes when they prioritize an emergency over proactive maintenance. In the long run, you may end up spending more on constant repairs than you would on a new unit.
• Less energy efficiency: Even if you spend a small amount of money to fix an older unit, you’re still paying more in operational costs than if you got a new one. As technology improves, newer models do the same work but require less energy to do so.
• Temporary fix: Repairs often address symptoms rather than the root causes of problems. While they can provide a short-term solution, underlying issues might still exist, leading to further breakdowns.

Air compressor replacement

Here are the drawbacks and benefits of relacing an air compressor:

Pros

• Improved energy efficiency: Newer air compressor models are designed with the latest technology that focuses on energy efficiency. Replacing an older unit can lead to significant energy savings in the long run, cutting down operational costs and benefiting the environment.
• Long-term reliability: You're less likely to encounter unexpected breakdowns or malfunctions with a new air compressor. This reliability means less costly downtime, especially with proper maintenance. 
• Latest features and technology: The features on new compressors enhance the overall efficiency and safety of your operations. Upgrading often means better control systems, improved safety features, and more. 

Cons

• High initial investment: A new unit, especially one with the latest features and specifications, can be a significant investment. You’ll need the budget for the capital expense, plus an understanding of the ROI to expect. 
• Installation and setup time: Replacing involves downtime and labor hours during installation. You may also run into challenges when integrating it with existing systems. This can add to the already costly time you’ve gone without a working compressor. 
• Waste of functional components: Even if an older compressor has issues, it might still have functional parts. Completely replacing the unit means “wasting” components that are still in good working condition.

How to decide whether to replace or repair a compressed air system

Besides weighing the pros and cons, there are a number of factors to consider about your specific system and facility when deciding whether to replace or repair a compressed air. The system's age, condition, parts availability, and operational requirements all play a role.

You also need to consider your immediate needs and the facility’s long-term operational goals. Remember, an informed choice saves time, energy, and resources in the future.

We’ll walk you through the factors to consider in this section. As you weigh everything, remember to ultimately prioritize what's most crucial for your operations. Make your decision based on your expertise, firsthand experience with the operation, and a thorough assessment of the current system's condition.

Repair your air compressor when: 

• Equipment is new: An air compressor's life cycle is crucial in this decision-making process. Typically, rotary screw compressors that are less than five years old are best repaired. Newer equipment tends to have fewer underlying issues, and their occasional glitches can often be rectified with straightforward repairs.
• Parts are inexpensive and widely available: One of the primary factors when deciding to repair is the availability and cost of replacement parts. If parts are easy to obtain and won't break the bank, repairing is usually the more efficient route.
• Installing a new compressor would be a complex process: Some compressors, due to their placement or size, might require significant effort and resources to replace. In situations where the installation of a new unit might involve the removal of walls or the utilization of specialized equipment like cranes, it's often more cost-effective to repair the existing compressor, despite its age.

Replace your air compressor when: 

• The compressor is not the correct size: Over time, operational requirements can change. If your compressor system no longer matches output demands, it's time to think about a replacement. Proper sizing is essential for optimal energy efficiency and performance. A unit that’s too small for the load will wear out faster than it should. The same can also happen with one that’s too powerful. 
• The unit is old: On average, industrial air compressors last up to 20,000 or 25 years. If your equipment needs major repairs when it’s nearing the end of its expected service life, it’s probably more economical in the long term to invest in a new, more energy-efficient model. That’s especially so if it’s no longer covered under warranty. 
• Repairs are too expensive: Replacement is often the better choice when repair costs can exceed half the price of a new unit. That’s especially so if your current compressor is old and no longer has a warranty. 
• Parts are expensive or difficult to obtain: As compressors age, finding replacement parts can become a challenge, both in terms of availability and cost. Difficulty finding parts, or justifying their costs, are signs that it's time to consider replacement. 

Preventing air leaks

An excellent way to extend the life of your air compressor, while also saving money on operational costs, is to prevent air leaks from forming in the first place. These lead to poor performance and excess wear and tear. They also reduce efficiency, resulting in higher energy costs and negative impacts to the environment. 

Proactive maintenance inspections every three to six months help you spot small problems before they become more severe and costly. That includes checking for leaks as well as rust. You should also regularly monitor the power supply, check for milky oil or excessive oil consumption and ensure the cooling system is functioning optimally.

Finally, installing an air flow meter with IO-Link capabilities will give you accurate real-time reporting so you don’t have to wait a few months to notice a leak. While no system will work perfectly forever, taking these proactive steps will increase your air compressor’s life, performance, and efficiency.