OIL CHECK 500: The Smart Solution for Continuous Monitoring of Residual Oil in Compressed Air
Oil vapor in compressed air is an often underestimated risk. It can not only lead to malfunctions and increased wear on machinery, but also compromise the quality of end products – a critical factor, especially in the pharmaceutical and food industries, where the strictest hygiene regulations and legal requirements apply. Compressed air quality also plays a crucial role in hospitals, for example, in medical devices or sterile areas.
With the new OIL CHECK 500 from CS INSTRUMENTS, an innovative measuring device is available that continuously and reliably monitors residual oil in compressed air and other gases such as N₂, CO₂, N₂/He, and N₂/H₂ – while meeting the highest purity requirements.
Why is compressed air indispensable in the pharmaceutical industry?
Wherever the highest demands are placed on process reliability—for example, in the pharmaceutical, food, or medical technology industries—the quality of compressed air is a crucial factor. It affects not only product purity but also the reliability and stability of the entire system. Since compressed air can come into direct or indirect contact with products, packaging, or system components, its purity is essential for a smooth and safe production process.
Especially in sensitive areas such as the pharmaceutical and food processing industries (e.g., tablet manufacturing, cleaning of equipment and containers, or packaging and transport of raw materials and finished products), even minimal contamination can have serious consequences—from quality defects and production downtime to risks to consumer safety. Continuous monitoring of compressed air quality is therefore indispensable to ensure ongoing process reliability, product quality, and system efficiency.
What are typical risks to compressed air quality?
Compressed air quality depends heavily on the ambient conditions, the treatment chain, and the compressor system. Various contaminants can negatively affect compressed air, thereby jeopardizing both product quality and process reliability.
Typical sources of contaminants include:
- Solid particles (e.g., dust): These enter the system via the intake air or are generated by abrasion within the system. High-quality dust filtration is therefore essential to reliably separate particles and protect downstream components.
- Water vapor and condensate: Moisture can lead to corrosion, biofilm formation, and disruptions in the production process. Dew point sensors from CS INSTRUMENTS enable precise monitoring of the moisture content and help ensure optimal dryness.
- Hydrocarbons and oil: Even the smallest amounts of oil vapor and aerosols can contaminate products or damage sensitive system components. The OIL CHECK 500 continuously monitors these critical parameters, ensuring maximum safety and traceability.
- Microorganisms from the ambient air: These can enter the compressed air and lead to hygiene risks – especially in the food and pharmaceutical industries. Regular testing and microbiological monitoring in a laboratory are recommended to verify the effectiveness of the treatment process.
Even oil-free compressors do not offer an absolute guarantee of 100% oil-free or germ-free compressed air. Therefore, in addition to regular maintenance, the quality of the intake air and the treatment components used is crucial for ensuring consistently high compressed air purity.
What standards, guidelines, and technologies ensure compressed air quality?
There are no uniform legal requirements for compressed air quality. Pharmaceutical companies and other industries with high demands therefore rely on established standards and regulatory guidelines to ensure compressed air purity.
DIN ISO 8573-1 defines globally recognized quality classes for particles, moisture, and oil in compressed air. In addition, VDMA standard sheet 15390 offers practical recommendations for selecting the appropriate quality levels, tailored to specific applications. Regulatory concepts such as GMP, FDA, and QRM further support companies in defining and complying with requirements.
A key aspect is that compressed air quality must always be adapted to the individual process: areas with direct product contact require significantly higher purity than, for example, control or technical compressed air.
To meet these requirements consistently and reliably, modern production facilities rely on continuous online monitoring of compressed air quality. This not only enables compliance with standards such as ISO 8573-1, but also precise batch traceability and the minimization of rejects. Immediate action can be taken in the event of limit exceedances, further increasing process reliability.
24/7 monitoring is now standard practice in pharmaceutical and food processing plants, as it not only ensures consistent compressed air quality, but also provides the necessary documentation for audits and inspections at any time.
OILCHECK 500: A new level of residual oil measurement
The OIL CHECK 500 sets new standards in the monitoring of critical compressed air parameters:
- Patented internal zero-point adjustment by varying different pressure levels – no external calibration required
- Interchangeable sensor unit: easy on-site recalibration, no need to send the device in for service
- Continuous residual oil measurement for compressed air and various gases
This device offers not only the highest measurement accuracy but also practical advantages in operation:
less effort, less downtime, maximum safety
CONCLUSION
The demands placed on compressed air in pharmaceutical production are high – and for good reason. Contamination by oil or other particles can have serious consequences. With modern standards, clear quality guidelines, and above all, innovative measurement technology like the OILCHECK 500, companies can meet these challenges.
Wherever the highest quality is paramount and promises are not enough, continuous and precise monitoring of compressed air is essential. This is the only way to ensure that product safety and process stability are maintained over the long term.
This holistic approach not only raises product safety but also process efficiency to a new level – for maximum safety and cost-effectiveness in demanding production environments.
Contact FILCOM for more information.
Do you have questions about the OIL CHECK 500 or would you like to learn more about monitoring compressed air quality in your production? Our expert Wilfried Leitenberger will be happy to advise you.
Wilfried Leitenberger
Managing Director FILCOM GmbH
- w.leitenberger@filcom.de
- +49 711 441 33 22-51