SULLIVAN-PALATEK • TECHNICAL RESOURCES
Industrial Compressed Air Systems in Indianapolis
A practical guide to specifying the compressor, storage, filtration, drying and controls as one coordinated system – with a direct path to Sullivan-Palatek’s online System Builder.
Why buy a complete compressed air system instead of just a compressor?
DIRECT ANSWER
An industrial compressed air system coordinates compressor capacity, storage, drying, filtration and controls to deliver the required CFM, PSI and air quality at the point of use. Reviewing the complete system helps avoid mismatched components, unnecessary pressure loss and inefficient operation.
Manufacturers across Indianapolis and Central Indiana rely on compressed air for CNC machining, assembly, pneumatic equipment, automation, packaging and material handling. If the system cannot deliver the right air at the point of use, production suffers – even when the compressor itself is operating.
What does compressed air system selling actually mean?
System selling starts with the plant’s application, not with a horsepower quote. The goal is to specify a reliable, efficient compressed air supply by examining the entire path from generation to the production machine.
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Measure average and peak airflow instead of assuming the current compressor is correctly sized.
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Define pressure at the point of use and quantify downstream pressure losses.
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Select dryers and filters for the required dew point and contaminant limits.
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Evaluate storage, controls, condensate management and future production changes.
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Compare capital cost, operating energy, maintenance and the consequences of downtime.
What equipment belongs in the industrial compressed air system?
| System element | Purpose in the plant |
|---|---|
| Electric rotary screw compressor | Produces required compressed air at rated airflow and pressure. |
| Air receiver | Buffers short-duration demand and supports pressure stability. |
| Air filtration | Removes specified particulate, liquid and aerosol contaminants. |
| Refrigerated or desiccant dryer | Controls moisture to meet required pressure dew point. |
| Controls and sequencing | Coordinates compressor operation as demand changes. |
| Drains and condensate treatment | Collects and treats condensate at planned points. |
| Distribution piping | Delivers adequate pressure and airflow to equipment. |
Every component affects the total result. An efficient compressor cannot compensate for restrictive filters, undersized piping, uncontrolled leakage or incorrectly selected air treatment without consequences for energy use and reliability.
How does Sullivan-Palatek’s online System Builder work?
The Sullivan-Palatek Complete Air System Explorer shows how compressed air generation, storage, treatment and condensate management work together. Its Build Your Air System tool accepts a preliminary design basis and presents compatible equipment stages that can be reviewed and adjusted before a formal quote.
VIEW THE ORIGINAL SYSTEM BUILDER IMAGE AND LIVE EXPERIENCE
What can a buyer do in the builder?
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Enter the required CFM, operating PSI and intended air-quality goal.
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Review a conceptual compressor, receiver, filtration, dryer and distribution arrangement.
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Adjust compatible components and inspect the active airflow and condensate paths.
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Submit the preliminary system for review by a Sullivan-Palatek sales resource.
ENGINEERING REVIEW REQUIRED
The online layout is a planning tool – not a final engineering design, equipment guarantee or binding quotation. Sullivan-Palatek confirms the final sizing, sequence, air quality, pressure losses, electrical requirements, installation and commercial terms.
How do you size an industrial electric air compressor?
Compressor horsepower is not enough to identify the correct machine. Selection starts with airflow, pressure, demand variation, air quality and the operation’s production schedule.
| Sizing input | What to verify |
|---|---|
| Airflow in CFM | Measure base load, average demand, peak events and leakage. |
| Pressure in PSIG | Start at the highest legitimate point-of-use requirement; add actual distribution and treatment losses. |
| Demand profile | Record loading and unloading across work shifts, breaks and process cycles. |
| Air quality | Document the necessary pressure dew point and ISO 8573-1 purity class, where applicable. |
| Expansion | Consider realistic future equipment, shifts and production requirements. |
Should your facility choose fixed-speed or VFD rotary screw technology?
Both technologies can provide dependable industrial air. Their economics differ by load profile, control method and overall system design.
| Decision factor | Fixed-speed | VFD / variable-speed |
|---|---|---|
| Air demand | Often appropriate when demand is steady. | Worth evaluating when demand varies. |
| Part-load operation | Efficiency depends on control mode and unloading. | Output can adjust within the designed speed range. |
| Initial investment | Often lower equipment cost. | Often higher equipment cost. |
| Best comparison | Measured full-load and unload behavior. | Measured demand profile and actual part-load power. |
| Multi-unit arrangement | Can serve as base-load machine. | Can serve as trim machine when appropriate. |
A VFD is not universally more efficient. If demand remains near full load, a well-selected fixed-speed model may be economically preferable. Use verified package data and measured operation to evaluate the alternatives.
How do air treatment, receivers and controls protect production?
| System feature | Why it matters |
|---|---|
| Refrigerated dryer | General plant-air moisture control; typical pressure dew point is around +38 F (+3 C). |
| Desiccant dryer | Often used when a much lower dew point, such as -40 F (-40 C), is required. |
| Filters | Provide the application-specific contaminant removal needed while limiting unnecessary pressure drop. |
| Receiver storage | Helps manage short demand fluctuations when properly sized with compressor controls. |
| Master sequencing | Coordinates multiple compressors to reduce ineffective operating combinations. |
| Zero-loss drains / oil-water separation | Manages collected condensate and supports environmental requirements. |
Food, pharmaceutical or direct product-contact processes may require validated air purity, additional filtration or oil-free equipment. Those requirements must be established before selecting the package.
What does the total cost of ownership look like?
Electricity is a substantial component of compressed air ownership. A simple estimate is:
ANNUAL ELECTRICITY COST
Average package input (kW) x Operating hours per year x Electricity rate ($/kWh)
| Illustrative operating input | Annual example |
|---|---|
| Average compressor package input | 100 kW |
| Annual operating time | 6,000 hours |
| Electricity tariff assumed | $0.12 per kWh |
| Annual energy use | 600,000 kWh |
| Estimated energy expense | $72,000 |
Example only. Actual expense will depend on measured package power, demand profile, utility tariff, demand charges and other fees.
For operations management and capital approvals, compare the installed system scope, annual energy, maintenance, quality risks, downtime exposure, warranty and future expansion. An inexpensive compressor may lead to an expensive system if those requirements are ignored.
How can CAGI data improve an industrial compressor comparison?
The Compressed Air & Gas Institute (CAGI) publishes standardized performance information for participating equipment. Useful comparison metrics include rated delivered airflow, operating pressure, total package input power, specific power and applicable isentropic efficiency data.
COMPARE LIKE WITH LIKE
Specific power (kW per 100 CFM) helps compare energy consumption at equivalent operating conditions. Lower specific power is generally favorable, but only when the pressure, rating conditions, control mode and actual demand are comparable.
Request the correct model-specific performance sheet and confirm results at the intended operating pressure. Sullivan-Palatek publishes CAGI data for applicable industrial products.
Are Central Indiana utility incentives available?
Qualifying efficiency projects may be eligible for utility incentives, subject to current rules, program budgets and application timing. Incentive evaluation belongs early in the project, before equipment is ordered or work begins.
| Electric utility | Potential program pathway |
|---|---|
| AES Indiana | Prescriptive rebates may cover eligible compressor VFD applications; custom incentives can support qualifying engineered compressed air savings. |
| Duke Energy Indiana | Smart $aver offerings may include prescriptive or custom opportunities for approved energy-efficiency upgrades and compressed air projects. |
Confirm eligibility directly with your facility’s electric provider. Preapproval requirements may apply; past program terms are not guarantees of current funding.
Which Indianapolis-area industries benefit from systems thinking?
| Sector | Typical system priority |
|---|---|
| CNC machining and metalworking | Stable pressure and adequate demand capacity for pneumatic tooling and machine functions. |
| Automotive manufacturing | Reliability, synchronized production demand and distribution performance. |
| Food and packaging | Application-defined moisture control, air quality and production uptime. |
| Life sciences | Documented air purity, critical process requirements and appropriate redundancy. |
| Warehousing and distribution | Shifting loads, storage and coordinated compressor controls. |
Indianapolis-area support includes Plainfield, Greenwood, Carmel, Fishers, Anderson, Kokomo, Noblesville, Lebanon, Greenfield, Brownsburg and Whitestown. Manufacturing is based in Michigan City, Indiana.
Why request a complete system evaluation from Sullivan-Palatek?
Sullivan-Palatek manufactures industrial electric rotary screw compressors in a published 5-450 HP range, including fixed-speed and VFD configurations. System proposals can address compatible dryers, filters, receivers, condensate-management hardware and controls as part of the same application review.
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Specify the actual CFM, PSI, electrical supply, operating hours and air-quality requirements.
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Evaluate a replacement compressor or a new coordinated system configuration.
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Review applicable published CAGI performance information and lifecycle operating costs.
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Request current pricing, lead time, treatment options and system review.
BUILD THE COMPLETE SYSTEM
Request a local system review, price and lead time.
Indianapolis Compressor Solutions
CALL 219-874-2497
Further reading: System Builder | Indianapolis Solutions | AES incentives | CAGI
Frequently asked questions
How do I determine the right CFM and PSI for a plant air compressor?
Measure simultaneous production airflow and required point-of-use pressure. Include verified downstream pressure losses, demand variability and realistic growth. Confirm model-specific compressor capacity at the target pressure.
When is a VFD compressor preferable to a fixed-speed compressor?
VFD equipment can be economical under variable loads within its efficient operating range. Fixed speed may be preferable at sustained loads. Compare measured demand, package power and lifecycle economics.
Can a refrigerated air dryer deliver a -40 F pressure dew point?
A conventional refrigerated dryer generally cannot achieve -40 F pressure dew point. Regenerative desiccant dryers are commonly used, subject to flow, inlet conditions and air-quality requirements.
What should I require in a complete compressed air system quote?
Request CFM at specified PSI, package input power, applicable CAGI data, controls, dryer and filter ratings, receivers, condensate plan, warranty, project scope and current lead time. Require final application review.
Application to equipment
Continue Your Compressed-Air Research
Connect this information with relevant applications, published equipment and technical references. Final equipment selection requires an application-specific review.