Supercharge Your Air Compressor

Demo compressor and tool.
(Photo: E.A.R.S.)

We live in a world of wasted energy. More to the point, automotive shops live in a world of wasted air. Shops are paid to run tools and equipment. Yet depending on the application, most of the energy and air supplied by compressors is blown into the work environment, with only a small portion actually being harnessed for the job. 

That's about to change. Exhausted Air Recycling System of North America (E.A.R.S.), based in Lindenhurst, IL, recently introduced its innovative E.A.R.S. system and air tools. Invented by Australian Chris Bosua, the technology has done for air systems what turbochargers did for engines. The E.A.R.S. system captures and recycles what would have been exhaust air and returns it back to the air compressor, with immediate benefits to shops and technicians.

The nuts and bolts "When an air tool is used, over 95 percent of the energy used to produce the air is wasted and exhausted out of the tool," says Cliff Kniesly, president of E.A.R.S. The patented E.A.R.S. system involves two simple steps that establish a closed-loop system to optimize the use of compressed air. 

Compressor Manifold
(Photo: E.A.R.S.)

First, a special manifold is installed on the compressor intake, which has an extra connector to receive exhaust air via a return air line. Second, air tools are fitted with an extra connector at the tool's exhaust port that sends the exhaust air back to the compressor through the return air line. 

In a conventional system, the air compressor takes in ambient air through a simple muffler system. With the E.A.R.S. technology, a manifold is fitted between the muffler and the intake of the air compressor. All return lines from the air tools or other equipment are routed back to this manifold. The low-pressure air in the return lines supercharges the compressor's intake. Most single-stage air compressors pull in one atmosphere of air. When fitted with the system's adapters, most of the return air from the tool is returned directly to the compressor, increasing the total supply to two atmospheres, says E.A.R.S. This effectively doubles the volume of air entering the compressor on each stroke. 

Air Tool Adaptor 
(Photo: E.A.R.S.)

The returned air also is cleaner and cooler than outside air, and does not affect operating pressures. This enables a much smaller compressor to be used - typically half the size - to do the same task. 

Moreover, while operating air tools, E.A.R.S.-equipped compressors don't have to cycle as often or as long to keep up with shop demands. 

Whether for a service and repair shop, tire shop, collision shop or mobile service, E.A.R.S. technology can be applied to any compressed air system, ranging from smaller 5-horsepower (hp) portable units to larger horsepower rotary screw models, and beyond to any manufacturing application using compressed air. 

The company also provides a number of traditional and innovative air tools, as well as retrofit kits that can convert most existing air tools in less than 20 minutes. In addition, retrofitted compressors also will be available. The system, tools and accessories will be distributed through OEMs, warehouse distributors, jobbers and independent mobile tool dealers. Shops can also order directly from the company at www.earsnorthamerica.com.

What's in it for you? For shops and technicians, the E.A.R.S. technology provides a number of benefits, as shown in the chart. Direct Benefits to Shops and TechniciansSupercharged air supply allows smaller compressors to be used to drive the same tools and equipment, reducing capital costs by as much as 35 percent.The system can recapture up to 80 percent of wasted energy. This can stretch a shop's energy dollar by reducing operating costs by up to 40 percent.Recycled air is pre-filtered. Equipped tools spread less dust, oil and dirt particles into the workspace, reducing inhaled particles and contamination of new finishes on vehicles.Equipped tools operate at noise levels reduced by 40 percent to 80 percent. The lower decibel levels help prevent hearing loss, while allowing conversations in the workplace to take place at normal levels.The system reduces moisture by up to 70 percent within the closed-loop air system, thereby prolonging the life of the tools, hoses and the air compressor.In addition to being a clean source of air, the recycled air helps compressors maintain adequate pressure for operating air tools.For shops that rely on a single large compressor, a smaller and less-expensive portable E.A.R.S.-equipped compressor can provide a practical backup to keep productivity up in the event the primary system breaks down.Nearly 80 percent of all air tools can be retrofitted with E.A.R.S. adapters. The company's line of proprietary air tools covers other applications.The system can provide more air and power to mobile equipment, where space is at a premium.Table: B. Chabot; Information source: E.A.R.S.

Switching to or installing an E.A.R.S. system and line of tools is simple and affordable, Kniesly says. He notes that typical shop-sized air compressors start near 7 hp and can range to as high as 50 hp for large shops with a number of applications. 

"We estimate the most common compressors to be in the 10- to 15-hp range, with an 80- to 120-gallon tank," says Kniesly. "A quality compressor in this range will cost between $3,800 and $8,000." 

Kniesly emphasizes that a shop specifying a shop air system to meet its needs would have to buy a larger capacity conventional compressor than if an E.A.R.S. system was used. "Typically, an E.A.R.S. system would require a compressor with up to 50 percent of the horsepower needed in conventional scenarios, without losing air pressure," he notes.

With energy being an ever-increasing expense, E.A.R.S. says its system and tools give a shop's energy dollar improved mileage: Less energy dollars are used to produce the same output as a conventional system. A smaller compressor with the E.A.R.S. system can save a shop on its capital expenditures, without sacrificing performance or results. Because the recycled air is cleaner than ambient air, it results in less wear and tear on the shop's air compressor. 

A healthy shop E.A.R.S. says its system provides several key benefits to worker health and safety. "Air tools' exhaust stirs up dirt, dust and even oil particles in the shop, often sending dangerous materials like brake dust and lead in the air that we breathe," says Kniesly. By capturing most of the exhaust air and recycling it back through the compressor, he explains, the E.A.R.S. system minimizes the dispersal of airborne substances in the trenches and bays where technicians work and breathe every day. Independent Noise Level Testing
Maximum Decibel (dB) Levels (Performed by Acoustics Pty Ltd.)Tool TestNoise Level 
With E.A.R.S.Noise Level 
Without E.A.R.S.1/2-inch Impact Wrench
  Free Running:
  Working:74.4 dB
97.5 dB97.0 dB
99.9 dBStandard Screw Gun 
  Free Running:
  Working:73.5 dB
85.4 dB93.8 dB
97.5 dB3/8-inch Drill 
  Free Running:
  Working:75.6 dB
87.3 dB87.9 dB
97.0 dB150mm Random Orbital Sander 
  Free Running
  Working85.8 dB
88.7 dB95.4 dB
90.8 dBTable source: Acoustics Pty Ltd. Prolonged exposure to the loud noise levels present in shop working environments has been shown to cause long-term hearing loss problems. Before debuting the E.A.R.S. system during the 2006 Industry Week, the company had its technology and equipment undergo independent noise testing by Acoustics Pty Ltd. (APL).  APL tested the E.A.R.S. system against a conventional system using four air-powered tools - an impact wrench, a screwdriver, a drill and a random orbital sander - in both free-running and normal working application modes. APL measured noise levels at the operator's ear as well as 1 meter away from the operator's hand.  Understandably, noise levels under work-load were significantly higher than in free-running mode. But in every mode, every distance and with every tool, APL concludes that the E.A.R.S. system resulted in significantly lower noise levels.  "It's important when looking at noise level data to remember that decibel ratings are logarithmic," Kniesly says. "A 10-decibel decrease in noise level is 10 times quieter. A 20-decibel decrease in noise level is 100 times quieter."  Given the test results, he adds, it is clear that the system has a substantially quieter impact on technicians' ears, in both day-to-day and long-term use. A full report of the testing methodology and results, as well as a demonstration of the E.A.R.S. technology, is available at www.earsnorthamerica.com and www.globalears.com.  So what's the bottom line for shop owners and technicians? If working in a cleaner and safer environment, lowering energy and capital costs, reducing noise, increasing productivity, and prolonging the life of air compressors and pneumatic tools matters, this technology is worth a serious look.(Sources: E.A.R.S North America, Acoustics Pty Ltd.)