What is the process of a two stage compressor?

When choosing between a single-stage versus dual-stage air compressor, you will want to explore the differences between each model and the power each one provides. From woodworking to beverage manufacturing, both types of compressors can power various tools and machinery, making the manufacturing process faster and easier.

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What Is a Single-Stage Air Compressor?

Also known as piston compressors, single-stage air compressors have pistons that draw air into the machine until it is sucked through a filter section. The air then passes through intake valves and into a cylinder, where a crankshaft rotates, and pistons push the air upwards. The piston helps compress the trapped air and force it through exhaust valves, which travel to a discharge tube and a check valve. Once the air enters a storage tank, it can stay until the user requires new air.

What Is a Two-Stage Compressor?

Two-stage air compressors &#; or dual-stage compressors &#; use a low-pressure, larger piston to draw in air. The air is sucked through a filter and passes the intake valve into a cylinder, where the crankshaft rotates, and a low-pressure piston pushes it upwards while compressing the air. The first compression also forces the air through a low-pressure exhaust valve which helps the air travel through an intercooler. 

After cooling, the air travels to the high-pressure sides of the compressor, where it is drawn into a cylinder and compressed a second time. Once it passes the discharge tube and check valve, it remains safely in a storage tank until the user requires new air.

Difference Between Single-Stage and Two-Stage Air Compressors

The main difference between single-stage versus two-stage air compressors is the number of times the air is compressed. While a single-stage compressor compresses air once, a dual-stage compressor compresses twice for higher pressure and power. 

Single-stage compressors suck air into a cylinder where the trapped air is compressed. After moving to a storage tank, the air can be used as energy for various tools. 

With a two-stage air compressor, rather than immediately going to a storage tank after compression, the air is sent to a smaller piston for the second round of compression. The double-pressurized air is also cooled before entering the storage tank, where the air can then be used as energy for high-powered tools and equipment. 

Uses for Single-Stage Air Compressors

A single-stage air compressor has many uses for providing energy for equipment. From woodworking tools to metalworking equipment, a single-stage compressor makes the production and manufacturing process more manageable. You can use single-stage air compressors in the following industries: 

Woodworking

Woodworking often requires a wide variety of intensive tools to make furniture, fixtures or other wooden features. However, without the help of power tools, woodworking may require extensive physical work, stamina and hand-eye coordination. If you want to cut boards and drill holes evenly every time, you can use air-powered saws and drills to assist your process. 

A single-stage air compressor powers these tools to help you achieve your goals in minutes rather than hours. A single-stage air compressor can also help power tools for the following tasks:

• Sawing: Whether you need to trim boards, cut shapes or saw panels, an air-powered saw can help make the process smooth and easy. While sawing may have once been a difficult and dangerous task, an air-powered saw allows you to saw with different blade lengths and board thicknesses safely.
• Nailing: Hammering may be a risky or awkward task. You risk bending the nail, hammering it crooked or hitting your thumb, the board or the surface underneath. However, an air-powered nailer helps you nail straight every time and finishes the task quickly.
• Drilling: Drilling holes relies on hand-eye coordination. However, operating a drill can be awkward or risky. You risk a wrist or elbow slipping, resulting in crooked holes or injury. With an air-powered drill, you can accurately make holes at a much faster speed. 
• Sanding: It takes powered machinery to sand the rough edges of the wood. While you could use sandpaper, it often leaves streaks and marks. An air-powered sander helps you sand in multiple directions while leaving a smooth finish without any streaks.

Metalworking

Any work involving metal is hard to accomplish without the proper tools. You need to cut, drill, mold and join pieces together, which is made easier with air-powered tools. Some tasks that might benefit from the help of air-powered tools include the following:

• Shearing: Metal alloys require specific molding needs. Using powered air metal-cutting tools, workers can cut through metal sheets as easily as cardboard. 
• Grinding: Whether you need to trim or grind tubes, pipes and bars, an air-grinder can do the job. It is handy if a piece of metal is too long and needs some trimming.
• Riveting: When fastening pieces of metal together, an air-riveter is one of the best ways to combine sheets and join seams. Riveting makes for a tight and secure fit, perfect when building sheds, structures and more.
• Ratcheting: If you need to undo metal fasteners, using an air-powered ratchet helps you break apart nuts that may have otherwise been impossible to disassemble. 

Uses for Two-Stage Air Compressors

Two-stage air compressors are often used for high-powered tools and equipment. Air compressors power essential tools from automobile assembly and beverage manufacturing to aerospace and military equipment.

Automobile Manufacturing

Constructing vehicles is a heavy-duty application that requires air-powered tools to save energy and assist in plant and repair shops. Automobile manufacturers may use two-stage compressors for the following tasks: 

• Lifting: During assembly, the frame and shell of the vehicle require lifting. A two-stage compressor can power lifting devices, making it easier for assembly lines to assemble cars quickly.
• Screwing: The engine parts also require screwing and bolting. Air-powered wrenches and ratchets help workers assemble and disassemble parts along the conveyor.
• Greasing: For parts in motion, the air compressors and the parts grind together require lubrication. Air-powered greasers help workers quickly apply lubricant to necessary machinery.
• Painting: Parts must be primed and coated evenly when painting vehicle shells. Using air-powered paint sprayers can produce a coating free of streaks and blotches.

Beverage Manufacturing

Companies use two-stage compressors during the beverage manufacturing process to power tools needed to produce massive amounts of soda, juice or alcohol. Beverage manufacturers may use air compressors for the following tasks: 

• Molding: Compressors mold the bottles out of glass, and air-powered dryers solidify the molds.
• Filling: Air-powered machines fill bottles of juice or soda during the conveyor process.
• Sealing: Air-powered machines extract air from the bottles and put on air-tight lids and seals.
• Labeling: Air-powered robotics apply labels and stickers.
• Packaging: Air-powered robotics neatly package bottles.

Aerospace and Military Equipment

When building aircraft, tanks or other military equipment, a two-stage air compressor helps generate enough power to assemble and finish each piece. Air compressors may also help with the following jobs:

• Cutting: Compressors can power machines to cut parts from raw metals and form molded parts using air-powered machinery. 
• Shaping: Manufacturers may use air-powered sawing tools to cut and shape wings, flaps, engines, rudders or propellers. 
• Assembling: Military equipment manufacturers assemble parts using air-powered fastener tools.
• Finishing: Air-powered blowers, sanders, painters and dryers can help finish the pieces with paint and decals.

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At Compressed Air Technologies, we offer air systems, parts and lubricants and perform preventative maintenance and repairs whenever you need them. As the leaders of compressed air tools for over 30 years, our systems have run efficiently and smoothly, helping maintain your equipment&#;s reliability. Contact us today to speak to a representative and explore our compressed air products.

Air compression systems are utilized in various domestic, commercial, and industrial applications. Depending on the intended application, a single or dual-stage compressor might be more appropriate. In this article, we will discuss how to differentiate between both variants as well as their benefits and uses.

Comparing Single Stage and Two Stage Compressors

The key difference between a single-stage air compressor and a two-stage unit is the number of stages involved in the compression process.

With single-stage compressors, air pulled into their intake valves is only compressed once before being channeled to either a storage unit or directly to an outlet for the intended application. By comparison, two-stage compressors subject the air from their inlets to two consecutive stages of compression at increasing pressures.

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Further, single-stage compressors are typically meant for use in smaller-scale applications and are usually driven by gas. Two-stage compressors are often powered by electricity and are useful in larger applications requiring compressed air.

How To Tell the Number of Stages on A Compressor Unit

The easiest way to determine the number of stages for an air compressor unit is to examine the cylinder sizes and count the number of air intakes present. Single-stage compressors will have cylinders of a uniform size, each with its air inlets, while two-stage compressors will have only one inlet valve and non-uniform cylinders.

Single Stage Air Compressors

Outlined below are the most important things to know when considering a single-stage air compressor.

Uses of Single Stage Compressors

Single-stage compressor units are popular with various woodworking and metal crafting applications. Some of these uses are described below.

Wood Crafting

Accurate wood cutting, assembly, and finishing require power tools that make the process easier, faster, and more efficient. Air-powered saws, nail drivers, drills, and sanding machines are effective choices for people working in wood crafting.

Metal Working

Most devices, machines, and equipment we use daily contain metallic components. Creating these components requires specialized tools to cut, shape, and assemble due to their higher tensile strength than other non-metals. Pneumatic compressors play a key role in shaping metals into the various configurations needed for varying applications.

Benefits of Single Stage Compressors

The main benefits of single-stage compressors are highlighted below

• Single-stage compressor units are cheaper than their two-stage counterparts
• Lighter weights make handling easier by single crew tradesmen
• Electric models are energy efficient

Two Stage Air Compressors

Highlighted below are the key uses and benefits of two-stage air compressors.

Uses of Two Stage Compressors

Two-stage compressors are well suited to various industrial-scale applications, including automobile assembly/repairs, aerospace engineering, as well as food and beverage manufacturing.

Automobile Assembly/Repairs

In automobile manufacturing plants, two-stage air compressors can drive various production stages, including lifting multiple vehicle components, including engine blocks, frames, and shells. Other uses include screwing and bolt fixation, greasing/lubrication, and finishing with paints.

Aerospace Engineering Applications

Two-stage pneumatic compressors are virtually indispensable in aerospace engineering. These powerful air compressors are integrated into different stages of aircraft manufacture, including component forging, cutting, machining, shaping, assemblage, fastening, and finishing.

Food and Beverage Manufacturing

In addition to locally sourced fresh fruits and foods, many food items consumed worldwide are prepared and packed in large quantities in factories. Commercial food and beverage preparation typically require two-stage air compressors to drive various processes, including the following:

• Mixing
• Chopping
• Frosting
• Filling
• Sealing
• Labeling
• Packing

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Benefits of Two Stage Compressors

The key advantages of two-stage compressors include:

• Improved efficiency with greater CFM of compressed air compared to single-stage units
• Run cooler, with less heat generation during routine operation
• Excellent for use in large-scale applications

How Many Compressor Stages Do I Need?

The number of compressor stages needed will vary between applications. For smaller scale, single tradesman work, a single stage compressor will perform excellently well. However, if industrial-scale manufacturing is the intent, then a two-stage air compressor is the more suitable option.

Contact NiGen to Learn More About One Stage and Two Stage Air Compressors

At NiGen, we are committed to providing all our clients with the best customer experience possible. We provide high-quality air compressor solutions easily modified to suit various unique applications.

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