Compressed Air Systems for Plastic Processing Plants
Plastics and rubber production, including injection moulding, blow moulding, extrusion, thermoforming, vulcanisation, conveying and conveying. Mould filling accuracy, product consistency and machine performance are impacted by pressure fluctuation, moisture carryover and/or unstable airflow. Frank Compressors is designing compressed air systems for the real pressure, duty and purity requirement of plastic and rubber plants throughout India with pan India service and spare parts support.
- Cut energy costs by 35%–50% with VFD demand matching.
- Improve yield by 10%–15% by eliminating surface defects.
- Recover 20%–25% of air capacity by reducing system leaks.
- Extend component life by 25%–30% with moisture control.
- Boost PET output by 10%–12% using high-pressure delivery.
Air Compressors for Plastic & Rubber Manufacturing Plants
Plastic and rubber plants operate across a wide pressure range depending on the process. Injection moulding lines typically run at 7 to 10 kg/cm², while PET stretch blow moulding requires up to 40 kg/cm² for bottle production. Poorly configured compressed air systems create pressure drops, energy waste, and product quality issues across production lines.
Frank Compressors builds systems around actual pressure zones, airflow demand, and air quality requirements for injection moulding, PET bottling, extrusion, thermoforming, and rubber processing plants.
Our range includes PET air compressors, high-pressure compressors, rotary screw compressors, VFD and PM motor systems, oil-free compressors, vacuum pumps, refrigeration dryers, and air receiver tanks.
Years Experience
Happy Clients
Countries Served
PET Air Compressors
Frank Compressors PET air compressors deliver clean, oil-free, and moisture-free high-pressure air up to 28 kg/cm² for continuous PET bottle and food packaging production. Advanced filtration systems help maintain contamination-free airflow across high-speed blow moulding cycles.
| Technical Feature | Specification Details |
|---|---|
| Models Available | PET-155I/500, PET-200I/500, PET-250I/500 |
| Maximum Working Pressure | 28 kg/cm² (398 PSI), Two Stage |
| Motor Power Range | 15 HP to 25 HP / 11 kW to 18.5 kW |
| Free Air Delivery | 45 CFM to 72 CFM |
| Tank Capacity | 500 Litres |
| Drive Type | Belt-driven heavy duty |
| Primary Applications | PET bottle blowing, beverage container production, food packaging lines |
High-Pressure Air Compressors
Frank Compressors high-pressure systems use three-stage compression, intercooling, and heavy-duty forged internals for sustained high-pressure plastic processing applications up to 35 kg/cm². Deep radial cooling fins and expandable filtration help maintain reliable long-hour operation.
| Technical Feature | Specification Details |
|---|---|
| Models Available | Giant-150H/500, Giant-200H/500 |
| Maximum Working Pressure | 35 kg/cm² (1,015 PSI), Three Stage |
| Motor Power Range | 15 HP to 20 HP |
| Free Air Delivery | 31.4 CFM to 37.7 CFM |
| Tank Capacity | 500 Litres |
| Compression Stages | Three-stage with intercooling |
| Primary Applications | High-pressure moulding, industrial pneumatic testing, rubber press operations |
Rotary Screw Air Compressors (Mute / Mute HD Series)
The Mute and Mute HD series deliver steady low-pulsation airflow for injection moulding, extrusion, and conveying systems operating continuously across production shifts. Oil carryover remains below 3 PPM, while low-noise operation helps reduce plant floor noise levels.
| Technical Feature | Specification Details |
|---|---|
| Power Range | 3 HP to 125 HP / 2.2 kW to 90 kW |
| Working Pressure | 7 to 13 kg/cm² |
| Airflow Capacity | 9.5 CFM to 572 CFM |
| Oil Carryover | Less than 3 PPM |
| Noise Level | 61 dB(A) to 74 dB(A) |
| Primary Applications | Injection moulding, plastic extrusion, conveying systems, clamping automation |
VFD Screw Compressors
Plastic and rubber plants rarely operate at one fixed air demand throughout the shift due to mold changes and varying production loads. Frank Compressors VFD systems automatically adjust motor speed within a 2 PSI control band, reducing idle power waste and lowering electricity consumption by up to 50%.
| Technical Feature | Specification Details |
|---|---|
| Power Range | 10 HP to 125 HP / 7.5 kW to 90 kW |
| Working Pressure | 7 to 13 kg/cm² |
| Airflow Capacity | 35 CFM to 572 CFM |
| Control Band | 2 PSI (vs 10 PSI for fixed-speed units) |
| Energy Savings | Up to 50% compared to fixed-speed operation |
| Primary Applications | Multi-line moulding plants, variable-shift thermoforming, packaging automation |
Permanent Magnet Motor Screw Compressors (Cute Series)
The Cute series combines a rotary screw air end with an IE4-grade permanent magnet motor designed for continuous three-shift plastic production. Its direct-drive design removes belt and gear losses while delivering up to 50% energy savings across high-volume operations.
| Technical Feature | Specification Details |
|---|---|
| Power Range | 10 HP to 125 HP / 7.5 kW to 90 kW |
| Working Pressure | 7 to 8 kg/cm² |
| Airflow Capacity | 45 CFM to 642 CFM |
| Motor Efficiency Class | IE4-grade permanent magnet |
| Transmission Efficiency | 100% (no belts or gears) |
| Load Control Range | 20% to 110% |
| Primary Applications | Large injection moulding plants, continuous extrusion lines, multi-shift plastic manufacturing |
Oil-Free Screw Air Compressors
During the manufacturing of food-grade packaging, pharmaceutical moulding and medical plastic production, 100% oil-free compressed air is necessary. Frank Compressors oil-free screw systems prevent the risk of contamination by employing dry compression chambers in addition to downstream filtration.
| Technical Feature | Specification Details |
|---|---|
| Power Range | 10 HP to 75 HP / 7.5 kW to 55 kW |
| Working Pressure | 7 to 10 kg/cm² |
| Airflow Capacity | 31 CFM to 354 CFM |
| Air Purity | 100% oil-free, dry compression |
| Primary Applications | Food-grade container moulding, pharmaceutical packaging, medical device production |
Piston Vacuum Pumps
In thermoforming, vacuum forming and blister packaging lines, stable vacuum conditions are required to guarantee the accuracy of the moulds and the wall thickness. Frank Compressors piston vacuum pumps remove gas and moisture from forming cavities for cleaner, more accurate plastic forming.
| Technical Feature | Specification Details |
|---|---|
| Mechanism | Mechanical piston vacuum generation |
| Primary Applications | Thermoforming, vacuum forming, blister pack lines, degassing of plastic compounds |
| Vacuum Function | Removes gas and moisture from forming cavities |
| Benefit | Ensures dimensional accuracy and wall thickness consistency in formed plastic parts |
Rotary Vane Vacuum Pumps
Steady, non-pulsating vacuum levels are obtained for rubber extrusion, thermoforming and vacuum forming processes with rotary vane vacuum pumps. For formed products, continuous vacuum stability contributes to dimensional accuracy and surface finish quality.
| Technical Feature | Specification Details |
|---|---|
| Mechanism | Rotating vane for continuous, non-pulsating vacuum |
| Primary Applications | Rubber extrusion, plastic thermoforming, vacuum forming, evacuation systems |
| Vacuum Stability | Continuous, pulsation-free vacuum delivery |
| Benefit | Maintains dimensional consistency and surface finish quality in vacuum-formed products |
Refrigeration Air Dryers
Moisture in compressed air systems causes silver streaking, surface bubbles, weak weld lines and rubber blistering during processing. Frank Compressors refrigeration dryers remove water vapour before air reaches the production network, which helps to protect the quality of the product and pneumatic systems.
| Technical Feature | Specification Details |
|---|---|
| Function | Condensation and drainage of moisture from compressed air |
| Primary Applications | Injection moulding, rubber vulcanisation, extrusion lines, pneumatic tool systems |
| Key Protection | Prevents silver streaking, surface defects, valve corrosion, and rubber blistering |
| Compatibility | Compatible with all Frank screw and reciprocating compressors |
Air Receiver Tanks (ARV Series)
Injection moulding lines often create sudden simultaneous pressure demand during clamping, injection, and ejection cycles. Frank Compressors ARV tanks store reserve compressed air to stabilise pressure and reduce compressor cycling across production lines.
| Technical Feature | Specification Details |
|---|---|
| Storage Capacity | 500 Litres to 10,000 Litres |
| Working Pressure | 7 to 45 kg/cm² |
| Compliance | ISO 9001:2015 certified pressure vessels |
| Primary Applications | Injection moulding lines, blow moulding pressure buffering, extrusion plant stabilisation |
How Compressed Air is Used in Plastic & Rubber Production
Injection Moulding
Clamping cylinders and ejector systems and core pulls are used in injection moulding machines by compressed air. Pressure variation affects mould filling speed and finished part accuracy.
PET Stretch Blow Moulding
High pressure compressed air exceeding 28 kg/cm² is used to stretch heated preforms into bottles and containers in PET bottle production. For food grade packaging applications, the air must remain free from oil and moisture.
Plastic Extrusion
Compressed air is applied for die adjusting, haul-off control and downstream cutting in pipe, profile and sheet production on extrusion lines.
Blow Moulding for HDPE & PP
To ensure uniform expansion of the molten parison against the mould wall during high speed blow moulding of HDPE and PP lines, a steady compressed air supply is required.
Thermoforming
Thermoforming combines compressed air and vacuum pressure to shape heated plastic sheets against mould surfaces. Unstable pressure affects wall thickness and product consistency.
Vacuum Forming
During forming, the heated plastic sheets are drawn tightly to the mould surfaces by vacuum pumps. Inconsistent vacuum depth causes surface flaws and part size variation in the final product.
Rubber Vulcanisation
Rubber moulding presses rely on compressed air to actuate some hydraulic systems and to control the timing of the vulcanisation cycles. Stable pressure aids in consistency of curing from one batch to another.
Rubber Extrusion
Rubber extrusion systems use pneumatic haul-off and cutting equipment during continuous profile and sealing strip production. Pressure fluctuation affects profile shape consistency.
Powder Coating on Plastic Components
Compressed air powers powder coating guns used on plastic automotive parts, appliance housings, and industrial components before oven curing stages.
Plastic Welding
Plastic hot air welding systems use heated compressed air to soften joint surfaces before bonding. Stable airflow and pressure directly affect weld strength.
Pneumatic Conveying of Plastic Granules
Compressed air moves plastic pellets, regrind material, and masterbatch granules through conveying pipelines from storage silos to moulding machines.
Mould Cooling & Purging
Compressed air removes residual plastic from hot runners during colour changes and helps cool mould surfaces between production cycles.
Leak Testing of Hollow Plastic Parts
Hollow containers, automotive ducts, and fuel tanks are pressure-tested using compressed air to detect leaks, cracks, and weak weld areas before dispatch.
Pneumatic Clamping in Rubber Press Lines
Rubber press systems use pneumatic clamps to hold preforms securely during moulding and trimming operation. Stable air pressure maintains consistent clamping force.
Spray Coating & Surface Preparation
Compressed air operates spray coating systems used on automotive plastic panels, consumer products, and industrial components before assembly. Clean dry air helps prevent coating contamination.
Film Blowing
Film blowing lines use compressed air to inflate molten plastic tubes into bubbles with controlled diameter and wall thickness. Airflow stability affects film width and gauge consistency.
Foaming & Foam Moulding
Compressed air helps expand foamed plastic compounds during moulding of insulation panels, cushioning materials, and automotive interior components.
Deflashing & Part Cleaning
Compressed air jets remove flash residue, dust, and release agents from moulded rubber and plastic parts before inspection and assembly.
Degassing of Plastic Compounds
Vacuum pumps remove trapped air and volatile gases from plastic and rubber compounds before moulding. This helps reduce voids and surface bubbles in finished products.
Automation & Robotic Part Handling
Pneumatic grippers, suction cups, and rotary actuators handle plastic parts across automated assembly and inspection lines. These systems require continuous stable compressed air during production hours.
Why Plastics & Rubber Manufacturers Choose Frank Compressors
High-Pressure PET Performance
Delivers clean, dry compressed air for PET bottle and blow moulding lines operating under continuous production conditions.
Complete Industrial Air Systems
Supplies compressors, PET systems, dryers, vacuum pumps, and air receivers as one integrated industrial setup.
20+ Years of Industry Experience
Supporting injection moulding, blow moulding, extrusion, and thermoforming industries across India since 2000.
How to Choose Compressors for Plastics Plants
Plastic and rubber plants operate across multiple pressure loads, making proper compressor sizing important for stable production efficiency.
Separate Pressure Zones
PET blow moulding operates around 28 kg/cm², while injection moulding commonly runs between 7–10 kg/cm².
Calculate Total Air Demand
Measure combined CFM demand from machines operating simultaneously during peak production periods.
Consider Startup Surge Loads
Simultaneous machine startups create temporary peak compressed air demand across production lines.
Add a 25–30% Buffer
Extra capacity supports leakage control, future expansion, and stable long-shift operation.
Get the Right Compressed Air System for Plastics Plants
Every plastics and rubber facility operates with different pressure ranges, airflow demand, and production loads. Share your plant requirements with Frank Compressors for a compressed air system recommendation tailored to your process conditions.
