Is Synthetic Lubricant Right for Your Compressor?

Now that you have invested in a centrifugal as your compressed air solution, it is important to understand the differences between using a full synthetic compressor lubricant and a general-purpose lubricant. The difference between the two options may surprise you. 

A general-purpose, mineral oil is derived from crude oil. The TurboCool Lubricant lineup includes options for both a fully synthetic gas-to-liquids derived and polyalkylene glycol lubricant engineered to suit the specific needs of a centrifugal air compressors, allowing cleaner machine operation, better protection for compressor parts, extended fluid life, and lower operating costs. 

What Is a Full Synthetic Lubricant for Compressors?

Why Choose a Synthetic Lubricant?

1. Cleaner Operation = Decreased Energy Consumption
   Unlike mineral oil, which can include a variety of impurities, a full synthetic compressor lubricant has a much higher purity and does not contain crude oil by-products that are natural starting points for varnish in compressors and deposits.
   Synthetic lubricants also have greater flash points than mineral oils, allowing your compressor the ability to run hotter and longer in higher temperature conditions as well as helping to keep your machine healthy during critical demand periods. A natural result of this purity is decreased energy consumption.
2. Handles Heat Better
   Compressors naturally generate a lot of heat, especially during periods of high demand. Synthetic lubricants are more stable at high temperatures. They won’t break down as quickly or form harmful deposits when the system gets hot.
   With a full synthetic compressor lubricant, your system can run longer without overheating, even in tough conditions. This can be especially helpful during summer or in manufacturing environments with constant heat.
3. Better Protection for Your Compressor Parts
   Using a full synthetic is going to give you a significant reduction of rust, corrosion, and varnish. In a centrifugal, varnish buildup is the enemy to your bearing surfaces. It is imperative that those surfaces remain varnish-free.  
   A clearance drop in the bearing clearances or varnish deposits on an impeller can lead to an increase in temperature, which, in turn, can lead to damaged bearings, loss of efficiency, or disruption of airflow.  
4. Extended Fluid Life
   Average mineral oil provides up to 8,000 hours of protection while a blend will offer up to 16,000 hours. A full synthetic will generally give you up to 24,000 hours of fluid life, extending plant maintenance intervals. 
   Even if the initial cost of the lubricant is somewhat higher than mineral oil, the extended fluid life, along with the other benefits of the full synthetic, add up to the most cost-effective solution.
5. More Cost-Effective
   A common myth in the industry is that synthetic oil is too expensive to use in the long run and does not provide a return on investment. The benefits a synthetic compressor lubricant offers to not only to your machine but also your overall operations make up for any cost difference.  
   
   In the long term, operators that opt to run their centrifugal air compressor with full synthetic can decrease maintenance costs by providing better protection of compressor parts and extending change-out intervals. As mentioned above, decreased energy consumption adds up to more cost savings.

How Does It Compare to Mineral Oil?

Here’s a quick side-by-side comparison to show how synthetic oil stands out:

While mineral oil might initially seem like a budget-friendly option, synthetic oil delivers better value in the long run.

How to Switch to Synthetic Lubricants the Right Way

If you’re thinking about making the move to full synthetic compressor oil, here are a few steps to follow:

1. Check Compatibility: First, make sure your compressor is compatible with synthetic lubricants. Most modern systems are, but it’s always best to consult the manufacturer’s recommendations before making a switch.
2. Flush the Old Oil: Before you start using synthetic oil, you may need to flush out the old mineral oil. Mixing the two can reduce performance and lead to a buildup of other issues. Starting with a clean system ensures you get the full benefit of the synthetic oil.
3. Choose the Right Product: Not all synthetic oils are created equal. Choose a fully synthetic lubricant that’s made specifically for centrifugal compressors and meets the technical requirements of your equipment.
4. Keep Testing the Oil: Regular testing is still important even with a high-quality synthetic lubricant. A quarterly fluid analysis can help you catch early signs of contamination, wear, or oil breakdown. This helps you avoid unexpected issues and keep your system running efficiently.

Fluid Analysis Still a Must 

Regardless of the type of lubricant used in your compressor, quarterly fluid analysis is vital to assess the health of your machine and prevent additional maintenance costs and downtime. Using a full synthetic lubricant and testing the fluids quarterly are key steps in ensuring a long life for your centrifugal.

This proactive approach can help prevent expensive repairs and unexpected downtime. Regular lubricant analysis can catch early signs of wear, contamination, or performance issues before they escalate. It’s a simple step that adds extra protection to your equipment and keeps your operations running smoothly.

How Synthetic Lubricants Support Sustainability Goals

Sustainability is becoming more important in manufacturing and facility management. The good news? Synthetic compressor lubricants support those goals in a few key ways:

Less Waste

Since synthetic lubricants last much longer than conventional oils, you’ll need fewer oil changes. This means less oil to dispose ofand a smaller environmental footprint overall. It’s a cleaner, more sustainable choice that helps reduce the volume of industrial waste leaving your facility.

Lower Energy Use

Synthetic oils help compressors run more efficiently, which means less electricity is needed to maintain performance. Over time, this adds up to significant energy savings, especially in systems that run continuously or in high-demand environments. Lower energy consumption also means reduced carbon emissions, supporting broader environmental goals, and avoiding cost fluctuations.

Longer Equipment Life

Synthetic lubricants extend the life of key compressor components by offering better protection against wear, rust, and heat-related damage. This means fewer breakdowns, fewer part replacements, and less manufacturing waste associated with equipment repairs or replacements. A longer-lasting compressor also means fewer resources used over time, which benefits both your budget and the planet.
 

What Should You Look for in a Full Synthetic Compressor Oil?

Not all synthetic lubricants are created equal. To get the best results for your centrifugal compressors, it's important to choose a product that’s truly built for the job. Here are a few key things to look for when selecting a full synthetic compressor oil:

• Meets OEM Requirements: Always make sure the oil is approved or recommended by your compressor’s manufacturer. This ensures it meets your specific equipment's necessary performance and safety standards.
• Strong Additive Package: A high-quality synthetic lubricant should include additives that fight off rust, corrosion, oxidation, and foam. These additives protect your compressor’s internal components and help the oil last longer.
• Proven Performance Under Pressure: Check that the oil has been tested and performs well in extreme conditions, like high temperatures, heavy loads, or continuous use. This is especially important if your compressor runs nonstop or in demanding environments.
• High Thermal Stability: Look for oils that can maintain their properties even when exposed to high heat for extended periods. This helps prevent breakdowns and buildup that can lead to maintenance issues or reduced efficiency.

Ready to Upgrade Your Compressor Oil? FS-Elliott Is Here! 

Switching to full synthetic compressor lubricant can be smart for facilities that want better performance, lower operating costs, and fewer maintenance headaches. If your compressors are running often, working under high temperatures, or if you’re looking for ways to reduce energy use and improve reliability, synthetic oil is worth considering.

Talk with an FS-Elliott Channel Partner or a lubricant supplier to find the right product for your system. They can help you evaluate options and make sure everything is set up for success. 

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