Above-deck compressors are the most popular with mechanic&#;s trucks since there is already room on the side pack, you can choose between rotary screw or reciprocating piston to meet air demands and they can be driven by either self-contained engines or vehicle hydraulics.

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When selecting an onboard air compressor, start with the basics. Determine how much pressure (psi) and flow (cfm) is required, then determine the duty cycle.

&#;Ask yourself what you will be doing with the compressor and then make sure you will not be overworking it,&#; advises Tim Worman, business development manager at IMT. &#;For example, if you run a 1-in. impact wrench 80% of the time, you would overwork a 35-cfm compressor. You would cycle the compressor more often and waste time while the air tank is refilling.&#; A compressor with a higher cfm rating would be more appropriate.

Evaluate tools used on a regular basis to determine power requirements. &#;The tools that you use most often need to operate with maximum efficiency and no downtime,&#; says Mike Pettigrew, marketing manager, VMAC. Consider air tool specifications as well as maintenance. &#;If air tools are improperly serviced, they require more air power to do the same job as a properly serviced air tool.&#;

Air flow is obviously the No. 1 requirement. &#;If you use multiple tools simultaneously, add their cfm together to be able to operate both at the same time,&#; says Jim Perschke, VP of Global Sales, Vanair Mfg. Most tools require 90 or 100 psi, though some may require 150 to 200 psi.

Once you determine the flow and pressure requirements, make sure the truck and/or PTO can handle the load. More horsepower is required for higher flows and pressures.

Drive Considerations

Power requirements also help determine the best compressor drive option. &#;In the 100- to 200-cfm range, the up-front cost of engine driven is significantly more than a PTO-driven compressor,&#; says Perschke. &#;In the 20- to 90-cfm range, the decision is really made by how the truck is equipped. Does the truck already utilize hydraulics or is it equipped with a PTO port for a hydraulic system? If the answer is no, then an engine-driven compressor is the right answer.&#;

&#;The most effective way to drive a compressor is largely dependent on the application,&#; says Worman. &#;While in the past, direct PTO drives were most common &#; partially because other options led to significant power inefficiencies &#; engineering improvements to these alternatives have increased the number of compressor drive options. If the machine already has a hydraulic system, a hydraulic compressor drive might be a simple solution.&#; If not, owners are increasingly choosing a gas or diesel engine rather than the truck&#;s main engine as the primary drive.

High-demand air applications still favor a PTO drive. &#;A simple rule of thumb: if the application requires more than 25 hp, the under-deck PTO drive is the right choice,&#; says Perschke.

Below-deck, PTO compressors are an alternative to a tow-behind. They are typically rotary screw designs capable of delivering 90 to 220 cfm of air. &#;If you used a tow-behind or skid-mounted compressor to perform your job in the past, then you would require more than 25 hp and would need a PTO-driven system,&#; says Perschke. &#;Under-deck air compressors will operate large pneumatic tools like jackhammers, rock drills and underground boring equipment.&#;

However, be careful to avoid common mistakes when selecting an under-body compressor. A common issue is not understanding what continuous-duty torque limitations exist, or how the truck needs to be ordered so that the under-body unit will fit properly. &#;Fuel tanks, exhaust, brakes, cab-to-axle, wheelbase and cab type all have an impact on the integration process,&#; says Perschke. Other issues include potential relocation of DEF tanks or 4x4 transfer cases.

Trucks can be factory equipped with connections to the engine and transmission control modules to improve the quality of compressor installation.

Engine-driven above-deck compressors save wear and tear on the truck&#;s engine and transmission. &#;Engine-driven, above-deck air compressors are often self-contained units, as they may have their own battery, fuel tank and air reservoir,&#; says Al Kuhlman, assistant product manager, Stellar Industries. Installation is simple: they can be bolted to the truck bed, have an airline run to the air filter/regulator and they&#;re ready to use.

Diesel and gas options are commonly available. &#;Diesel engines are significantly more expensive,&#; says Perschke. &#;It might make sense to choose one over the other if the operator plans to use chassis fuel rather than having to constantly fill the compressor&#;s fuel tank.&#;

Reciprocating vs. Rotary Screw

While other types of air compressors exist, the dominant configurations are rotary screw and reciprocating.

Reciprocating compressors come in single-and two-stage variants. The single-stage version uses one piston stroke to compress the air, and the two-stage compressor has two separate compression strokes. The first compression stroke partially compresses the air, then sends it to a second compression stroke to complete compression. The key difference is that the two-stage compressor will have an easier time keeping up with constant demand, such as that created by an impact wrench.

The single-stage compressor can save up-front cost in less demanding applications. They generally offer pressures from 70 to 100 psi, while two-stage compressors are often used for higher pressures from 100 to 250 psi.

Rotary screw compressors typically utilize two precise meshing rotary screws to compress the air between them. They can provide high volumes of high-pressure air at a continuous duty cycle for high-power air tools, such as jackhammers. In addition, they are a relatively simple design with no valves. They provide instant air on demand but do require very high rotor speeds.

&#;Rotary screw compressors and reciprocating piston compressors each have unique benefits, and IMT offers both types to provide our customers with the best option to meet their specific needs,&#; says Worman. &#;Today&#;s larger equipment is creating a greater demand for air to get the job done. So when an operator needs a continuous supply of air on demand, it makes sense to invest in rotary screw compressors. These units are designed to run for extended periods of time.&#;

Although rotary screw compressors don&#;t require a reservoir tank, IMT recommends utilizing a tank to help dissipate heat and remove moisture from the air. &#;In addition, a reservoir tank provides operators with a quick burst of air without the need to power up the compressor,&#; says Worman.

Rotary screw compressors are not necessary for short, intermittent air needs. &#;For those applications, a reciprocating piston compressor is likely the best option,&#; says Worman. &#;If you are not operating anything more than a 1/4-in. impact wrench, you are probably just fine with a reciprocating compressor. Be realistic about your use, and don&#;t buy purely on price.&#;

Each compressor type has unique characteristics. &#;Rotary screw compressors generally produce more cfm output for their footprint, but a two-stage reciprocating compressor can produce higher pressures,&#; says Kuhlman. &#;Since reciprocating compressors have more moving parts, they tend to be heavier than rotary screw compressors and take up more space.&#;

Also consider return on investment. &#;When up-front cost is the primary driver, the reciprocating air compressor is the cheaper solution,&#; Pettigrew points out. &#;When jobsite performance and job cost are the primary drivers, then the rotary screw will provide a better long-term return on investment.&#;

But there will be trade-offs with any choice. &#;The size of the compressor and the materials used in its manufacture will all impact weight, performance, maintenance and life expectancy,&#; says Perschke. &#;It is very difficult to get everything. For example, a cast iron reciprocating compressor might be heavier than an aluminum design; however, the cast iron design will last longer. A reciprocating compressor requires an air storage tank, whereas rotary screw compressors do not.&#;

Choose the Best Placement

Above-deck compressors are the most popular for mechanic&#;s trucks since there is already room on the side pack.

&#;Under-body air compressors are used when a lot of air is required and the customer has the ability to run two PTO units or only needs an air compressor and does not run other PTO-driven equipment,&#; says Kuhlman.

&#;Under-hood air compressors are another viable option when there are space constraints either on the truck&#;s transmission or in the truck&#;s bed,&#; he continues. &#;Under-hood air compressors are a great option when using a van body as a work truck platform, since there is very little vehicle work area taken.&#;

Consider both the vehicle and your specific requirements for a compressor when deciding upon placement. &#;To determine whether an under-hood, under-body or above-deck air compressor is most appropriate for my application, I need to consider the design of my truck body, including space and weight limitations,&#; says Pettigrew. &#;The amount of air I require for my tools or application is critical at this point, as this may reduce the number of available options. I also need to determine which power source I have available on the truck, including PTO and/or hydraulics. Lastly, I need to understand my applications, and what other equipment may be needed on the jobsite, such as a crane, welder, generator or booster.&#;

Avoid Common Mistakes

Make sure you understand compressor duty cycle. &#;One of the most common mistakes is choosing an air compressor that requires a 100% duty cycle in an application that would require one with less,&#; says Kuhlman.

&#;One example would be choosing a rotary screw compressor and operating it periodically. Rotary screw compressors work best when allowed to get to their operating temp and run there for a period of time greater than 15 minutes,&#; he explains. &#;This allows the moisture to evaporate out of the oil in the compressor, saving on maintenance requirements. In this instance, a reciprocating compressor would be best.&#;

Avoid under sizing to save up-front cost. &#;You may go with a smaller cfm air compressor to save money up front, but your application requires more air flow than what the compressor can efficiently produce,&#; says Kuhlman. &#;This leads to increased duty cycles and premature wear on compressor components, and ultimately replacing the compressor.&#;

Also avoid purchasing simply based on past history. Advancements in air compressor technology have given customers many new options. Research all options and technology advancements.

&#;Air compressors are one of the most important pieces of equipment on the jobsite and deserve the necessary attention to ensure the best solution is specified for the application,&#; says Pettigrew.

Invest the time to understand both the application and work environment. &#;This includes speaking with operators on the jobsite and learning about their challenges, and how they truly use the truck and air compressor,&#; says Pettigrew.

&#;An example of how purchasing may make a mistake is if they specify an air compressor that has its own engine power so that the truck engine does not have to idle. This is a great idea on the surface,&#; he notes, &#;but in reality, the operator may continue to idle the truck engine because they need to keep the cab heated in the winter and cooled in the summer.&#;

Portable Air Compressor Buyer's Guide

How to Pick the Perfect Portable Air Compressor

Portable air compressors go wherever the job is. 

Whether you want to mount a portable air compressor on your truck, wheel it around the job site, or carry it anywhere, there's a portable compressor that fits any job&#;and any user.

This guide will help you choose the right portable compressor: one you can easily take up on the roof, under the deck, or on the road. We typically recommend customers look for compressors with enough CFM (Cubic Feet/Minute) and PSI (Pounds per Square Inch) to meet the job's demands.

1. Hand-Carry Air Compressors

Hand-carry air compressors are the smallest and easiest to move around. If your compressed air needs include inflating balls, mattresses and tires, hobby work, and other light-duty applications, these are the compressors for you. They are available in a variety of sizes and are mostly electrically powered, with some exceptions of those needing gasoline instead.

Hand-Carry CompressorsInflatorsPancake CompressorsHot Dog CompressorsTwin-Stack CompressorsUsesEmergency car tires, inflatables, bike tires Entry-level uses; car tires; some air toolsHome DIY projects; most air toolsProfessional carpentry/ contractor workCFM0-2 CFM0-4 CFM0-5 CFM2-7 CFMMax PSI60-230 PSI90-135 PSI110-225 PSI120-175 PSIHP0-1 HP1-5.5 HP0.5 - 2 HP1-6 HPPower Source(DC) 12v/24v or (AC) 120v115-120v Electric & Gas110-120v110-230v Electric & Gas

Air Inflators

Mostly reserved for emergency use, high-quality inflators are extremely useful if kept in your car's trunk. They come in 12-volt, 120-volt, and cordless battery power options and are also the smallest consumer air compressors available.

When choosing an inflator, it's important to understand that it is not designed or meant for tasks other than inflating pool toys, bike tires, or small vehicle tires&#;in other words, it can't power air tools or fill RV-size tires.

Pancake Air Compressors

Pancake air compressors are portable, require minimal maintenance, and are easy to use. They are basic entry-level compressors with small tanks and are used for small projects around the house.

Pancake compressors are small and portable, making them a simple tool you can pull out and use at a moment's notice. Most have regulators and gauges so you can monitor your PSI, too. Some lighter air tools can be used with pancake compressors; however, due to their smaller air capacity, you may need to wait for the tank to refill often.

Hot Dog Air Compressors

Link to Comair

Hot dog air compressors get their name from the fact that their elongated tanks resemble hot dogs. They usually come in 1-7 gallon tank sizes. The size of the tank determines how long an air tool can be used before the compressor kicks on, called its duty cycle.

Two features you should look for are a durable carrying handle and rubber feet to prevent scraping floors. Three-gallon (all-in-one) air compressors are great for small projects around the house and come with the most common attachments for small jobs. They are compact, lightweight, and extremely versatile machines.

You can use these compressors with most air tools, but if you plan on using heavy-duty professional pneumatic tools like a nail gun for a flooring project, you should consider the largest hot dog compressor tank available, or a twin-stack compressor (below). 

Twin Stack Air Compressors

Twin Stack air compressors have two tanks, so you won't spend nearly as much time waiting for your tank to fill as with other types of hand-carry compressors. With the second tank, they can consistently power most air tools with minimal downtime.

Most consumer-grade twin stack compressors are direct drive, and they require much less maintenance than belt-drive compressors, with the added benefit of not worrying about oil changes and belt replacements on oil-free models.

Like most portable compressors, twin-stack models are offered as oil-lubricated or oil-free. Oil-free twin stack compressors do not need to be maintained. If you are using an oil-lubricated pump, make sure to check the oil&#;if there is no oil to lubricate an oiled pump, the compressor will wear out sooner. 

2. Wheeled Portable Air Compressors

Air compressors with wheels are often classified by either having vertical or horizontal tanks. Wheeled compressors are available as either electric or gasoline-powered.

Unlike hand-carry compressors, these units have wheels because they are much heavier, so they need to be pushed or pulled to wherever they are needed.

Wheeled CompressorsVertical CompressorsHorizontal CompressorsWheelbarrow CompressorsUsersConsumers and hobbyistsProsumersContractorsCFM3-10 CFM2-27 CFM5-18 CFMMax PSI115-225 PSI120-180 PSI125-175 PSIHP1-4 HP1-14 HP1-14 HPPower Source

Electric Only (110-230v)

Electric (110-230v) or GasElectric (110-230v) or Gas

Portable Vertical Tank Air Compressors 

Portable vertical tank compressors are essentially the same as horizontal units below, just with a different tank orientation and electrical power. If you're debating between the two, your storage space should dictate which style you purchase.

If you're re-siding a home, building a deck, or framing an addition, a major benefit of the vertical orientation is eliminating the need to bend over to use the compressor.

A major difference between the horizontal and vertical air compressors is there are no gas-powered vertical models. If you need to work away from electricity and need significant CFM or PSI, horizontal portable compressors will likely be your best option.

  

Portable Horizontal Tank Air Compressors

Portable horizontal compressors are popular because they have more power than hand-carry units. In most cases, they are very similar, just with larger tanks and more costly components.

These single stage compressors are popular with carpenters because, with their large tanks, they don't need to run constantly to refill.

Horizontal compressors are also available as electric or gas-powered, so you'll need to decide ahead of time where you'll be using your compressor and how much CFM you need.

Wheelbarrow Air Compressors

When you need durability and mobility, choosing a Wheelbarrow air compressor might be exactly what you need. With single or double wheels and sturdy handles, you can pull wheelbarrow compressors weighing upwards of 300 lbs through tough, uneven terrain.

Wheelbarrow compressors are designed for professional tradesmen on the job site. They are built with larger air tanks and heavy-duty materials so they can handle challenging conditions and withstand the normal rigors of a job site.

You can choose between gas-powered or electric-powered models, single or two-stage motors, and single and two-wheeled varieties. Some compressors even offer dual-air outlets to power two air tools simultaneously.

3. Mobile Air Compressors

Mobile air compressors are as portable as the vehicle they're attached to. This category includes truck-mount, tow-behind, and DC compressors, each with unique applications and uses.

Truck-mount compressors can be found mounted on roadside service vehicles, and tow-behind compressors are often towed with construction trucks. DC compressors are designed to inflate punctured tires and power air tools on the go, making them perfect for off-roading in Jeeps and UTVs, or vehicles that use air-ride suspension.

Mobile CompressorsDC CompressorsTruck-Mount CompressorsTow-Behind CompressorsUsesOff-roading, air-ride suspension, semi-trucks, agricultural equipmentMobile contractor, farmer, and construction applications Industrial construction applicationsCFM0-8 CFM13-57 CFM90-790 CFMMax PSI100-200 PSI150-200 PSI100-150 PSIHP0.25-2 HP8-18 HP24-254 HPPower Source12-24vGas OnlyDiesel Only

DC Air Compressors

 

DC (direct current) air compressors open up new possibilities that gasoline or electrically-powered compressors can't offer by running on battery power instead. These types of compressors don't normally have air storage tanks, meaning they run constantly, and many models boast a 100% duty cycle rating (always running).

Because they are battery-powered with either 12-volt or 24-volt currents, you can use them virtually anywhere, including permanently-mounted on your jeep, ATV, semi-truck, or agricultural equipment. You'll even find these compressors being used for air-ride suspension applications on vehicles.

With a DC compressor, you can go off-roading with ease, knowing you don't need to rely on plug-in power to prevent your tires from going (too) flat on you up in the mountains. Also, on rocky tracks, you won't have to worry about spilling gasoline or losing the gas tank, either.

Truck-Mount Air Compressors

Truck-mounted air compressors deliver heavy power from an even heavier compressor, supplying CFM and PSI levels of a two-stage compressor. As such, these compressors need to be transported in the bed of a work truck. You'll get the power of a stationary compressor with the convenience of portability.

For professional contractors or hard-working farmers, these compressors offer amazing value on job sites or in remote places. Just remember to bring extra gasoline because they are gas-only and can't be powered by electricity.

Tow-Behind Air Compressors

Tow-behind air compressors are behemoths of compressed air power. Up to 120 HP and over 375 CFM, these 2-stage rotary-screw compressors rival industrial stationary compressors.

Too powerful and large to fit into the standard truck bed, most require a hitch and a sturdy set of wheels to transport them to the job site. However, some will fit into the beds of larger tractor-trailers and can even be purchased without the trailer (skid-mounted). Either way, with a compressor like this, sandblasting, graffiti removal, pavement breaking, post-pounding, and more have never been so simple.

Because of their size and horsepower, they can deliver as much consistent power as a 2-stage stationary compressor with the benefit of being out in the field. These professional compressors also come with options for extended warranties and cold-weather protection kits and are highway tow-able (up to 55 mph). 

The Best Portable Air Compressors

We know it can be difficult to choose the right type of portable air compressor, so we've created tools to help make the decision simple. What better way to discover the best portable air compressors than by hearing what our customers actually think?

Click the link below to view the best portable air compressors of the year, as voted by our air compressor experts and customers who have purchased, used, and reviewed their own compressors. Or, if you need more help, give us a call.

Air Compressor Buyer&#;s Guide Navigation

Ultimate Compressor Guide | Air Compressors 101 | For Homeowners | For Contractors | Stationary Compressors | Portable Compressors | Quiet Compressors | Energy Efficiency | Air Treatment Systems | Air Filters 101 | Air Tools 101 |

By Melissa C.

Air Compressor Expert

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