One stage vs. Two stage compressor

The specs on single vs. two stage on the decent compressors are very similar, especially at 90 or 100 psi, but I am thinking that the headroom of the 2 stage will have a good benefit. My 5hp advertised (3hp actual) 60 gallon compressor died. It was single stage and rated at 50% duty. Die grinders were just about out of power when it turned on at 90 psi at the tank. There was only 30' or so of 3/8" line to the tool and a 1/4" coilhose pnuematics curly hose at the end of that. It would fill to 120 psi and shut off. The compressor was rated at 10 cfm at 90 psi.

I am looking at the PolarAir/Eaton 5hp 60 gal 2 stage. At 145ps shut off, I will have more reserve. It should be easy to get 90+ at the tool. It will turn on at 100 psi, so hopefully I will maintain 90 at the tool, and it will make 19 cfm (double my old compressor) so it can refill the tank quickly. The pump will put out more pressure, but I don't know if the tank is rated more than 145 psi. Maybe the control can be set to come on at 110 instead of 100 psi, but still turn off at 145.

Does anyone know what the PolarAir/Eaton tanks are rated at?

With the specs being so close, and the price pretty close on single vs. 2 stage, I planned to just buy a 2 stage.

Electric tools are more efficient for energy use, but the die grinders are small and light weight. I really love the IR composite 90 degree die grinder with a 3" flap disc for blending small weld areas and corners of metal. The sandblast cabinet beats grinding or any electric method when parts need cleaned up.

On one hand, I don't use air all of the time, but on the other, it has sucked to use my little compressor or the last week. Eaton seems like the best bang for the buck for a home user that might use it once a week, or may end up with a professional/side project that could require it for days in a row. I don't always need air, but when I do, I need a lot of it.

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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.

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.

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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.

To learn more about our commercial air compressor products and services, please contact us online today!

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