What is an Aftercooler & Why do They Matter?

Imagine you’re on a construction site in the middle of summer, and your portable air compressor is running nonstop. The air coming out is hot - as expected - but you might not realize it’s also saturated with moisture. If that moisture-laden air enters your tools or equipment, you’re looking at corrosion, clogs, and costly downtime.

Fortunately, aftercoolers can prevent these issues by cooling the compressed air and forcing moisture to drop out before it causes problems.

What is an Aftercooler?

An aftercooler is a cooling checkpoint for compressed air. As air exits the compressor, its temperature can soar to 200°F in oil-injected systems and up to 350°F in oil-free rotary screw compressors. This extreme heat holds more moisture, increasing the risk of water vapor condensing in air lines and damaging equipment. By cooling the air, aftercoolers force moisture to drop out, resulting in air that’s drier, denser, and far less likely to corrode components or cause system inefficiencies.”

Aftercoolers mitigate this risk by cooling the compressed air, causing moisture to condense and drop out of the system. This protects downstream components and also increases air density, allowing for more efficient operation.

Key Benefits of Aftercoolers, Backed by Data

By effectively cooling hot, moisture-laden air, aftercoolers prevent corrosion, enhance energy efficiency, and extend the lifespan of air-powered equipment. But how impactful are they really?

Moisture Reduction: Cooling compressed air can remove up to 75% of moisture content, effectively reducing corrosion and preventing equipment damage.

Energy Efficiency: By reducing moisture, aftercoolers lessen the load on downstream dryers, leading to notable energy savings. For example, systems incorporating aftercoolers have reported a 33% reduction in desiccant consumption, resulting in substantial cost savings over time.

Operational Savings: Implementing aftercoolers can cut maintenance costs and extend the lifespan of air-powered tools and machinery. Compressed air systems operating at optimal temperature and humidity levels require less frequent servicing, reducing downtime and expenses.

Applications & Real-World Impact

Aftercoolers are versatile solutions for industries where the temperature of compressed air can threaten equipment integrity.

Here’s how they’re applied:

1. Portable Air Compressors: Essential for On-Site Jobs

You’ll see portable air compressors at construction sites, bridge blasting projects, and highway repair zones. But many overlook the impact of hot, moisture-laden air on tools and equipment.

On a hot day, the air exiting a portable compressor can carry significant moisture, risking tool corrosion and freezing in winter. The Cool Pak by Van Air Systems offers a robust solution, cooling the air to optimal levels. It’s designed for 185 CFM compressors, featuring a 12 VDC motor, 25-micron air filter, and bulk moisture separator—all mounted on a portable aluminum stand with a rock guard and cord wrap for added durability.

Here is a look at the Cool Pak PRO Aftercooler System

2. High-Performance Engines

High-performance engines, particularly those with turbochargers or superchargers, compress air to boost power. But with compression comes heat, and if that hot air enters the cylinders, it can cause pre-ignition or detonation (a recipe for engine damage).

By cooling the air before it reaches the engine, aftercoolers increase air density, allowing for more fuel combustion and, subsequently, greater power output. This cooling effect can be the difference between optimal engine performance and a costly repair.

3. Industrial Applications: Blasting, Painting, and More

In industrial settings, aftercoolers ensure that air used for sandblasting, painting, or pneumatic tools remains dry and debris-free. Moisture in compressed air can cause clogs, clumping of blasting media, or improper spray patterns.

The Cool Pak PRO takes moisture control to the next level. Designed for portability and heavy-duty use, it features:

• An oil-less air motor, reducing maintenance needs.
• A wheeled cart design for easy maneuverability on job sites.
• A dual-position orientation, allowing operators to lay it flat to enhance moisture removal.
• 250 CFM capacity, making it a powerhouse for larger industrial applications

Why Invest in Aftercoolers?

Beyond moisture control, aftercoolers provide tangible operational benefits, from reducing desiccant consumption to preventing costly equipment breakdowns. In high-demand industries where downtime is money lost, integrating aftercoolers like the Cool Pak and Cool Pak PRO can be a game-changer.

For those on job sites or managing high-performance engines, investing in a reliable aftercooler system is a straightforward way to enhance efficiency, protect equipment, and cut operational costs.

Ready to learn more? Contact Van Air Systems at 1-800-840-9906 to discuss the best aftercooler solution for your application.