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The benefits of electric air compressors

Hitachi Global Air Power’s new Sullair portable air compressor is designed for long-term cost savings and a lower environmental footprint

Product image of the Sullair E425H electric air compressor.

The demand for cleaner, more sustainable alternatives to diesel-powered air compressors is rising as industries seek to reduce emissions, decrease fuel dependency, and adhere to evolving environmental regulations. The Sullair E425H, a fully electric rotary screw portable air compressor introduced by Hitachi Global Air Power, is designed to address these industry needs. The E425H is an option for field operators aiming to transition away from diesel without sacrificing performance.

The E425H builds upon the advancements introduced with the E1035H, an earlier Sullair model that intended to redefine what an electric portable air compressor could be. The E1035H, which launched with a 250-hp motor and the capability of producing 1,035 cubic feet per minute (CFM), provided a high-output solution for demanding applications. 

Recognizing the need for a more compact, versatile option, Hitachi Global Air Power introduced the E425H. Designed for applications that require less CFM or lower flow rates, the E425H delivers 425 CFM with an adjustable pressure range of 100 to 150 pounds per square inch (PSI), making it well-suited for jobs where 125 PSI is the standard requirement. Unlike past electric portable compressors, which were often stationary units mounted on trailers, the E1035H represented a complete rethinking of electric portability. The E425H follows a similar path, incorporating the same innovative approach but in a smaller, more accessible package that enhances flexibility across various environments.

According to Jerel Cole, senior product manager with Hitachi Global Air Power US, the E425H is poised to meet the growing demand for emissions-free, low-maintenance air compression. "With this design, we worked closely with our distributors, some end users, and our customers to truly understand their needs and requirements. Their main concerns were mobility and also the ability to function and operate in rough and dirty environments. For them, it was a reduction in total cost of ownership, it was having the ability to quickly get the machine up and running, it was a product that was extremely reliable for the rental market."

The E425H electric portable air compressor is designed for rapid deployment with set-up times as short as 15 to 30 minutes.

The shift from diesel to electric

A move toward electric air compression is one way contractors can shift thinking on efficiency and long-term cost savings. The emission-free E425H makes this air compressor a practical solution for operations looking to reduce their environmental footprint. Unlike traditional diesel-powered compressors, this machine produces no exhaust fumes, allowing it to be used in indoor environments where air quality is a concern.

In addition to benefitting from reduced environmental impacts, businesses can cut operating costs with the E425H. With diesel-powered units, owners must factor in regular refuelling, oil changes, and extensive maintenance. This electric model eliminates fuel costs entirely and significantly reduces the need for servicing. "Customers are looking for lower total cost of ownership, quick set-up, and reliability, and the E425H delivers on all these fronts," says Cole.

Another significant advantage is noise reduction on job sites that struggle with excessive noise pollution. The E425H runs more quietly than a diesel compressor, making it more suitable for locations where noise restrictions or worker safety concerns are paramount.

Innovation and performance

Hitachi Global Air Power's latest Sullair compressor offers an alternative for operators focused on sustainability but not at the cost of functionality and efficacy. The E425H is loaded with features designed to enhance performance and ease of use. One of its most significant advancements is the patent-pending condensate management system. Instead, it uses an internal heating element to evaporate excess moisture, reducing environmental impact and simplifying maintenance. "This system eliminates time-consuming and costly third-party disposal, which is a huge advantage for job sites with strict environmental controls," explains Cole. "It's an age-old concern within the industry, and so we've developed this solution based on the voice of [our] customers."

Another innovation is the swing-out cooler design, which allows for easy access during maintenance. Unlike traditional compressors that require cumbersome disassembly for cleaning, the E425H's redesigned cooling system improves airflow and prevents overheating. "The swing-out coolers mean technicians can clean the unit faster and more effectively, reducing downtime," says Jennifer Ohlinger, senior communications manager with Hitachi Global Air Power US.

The E425H also features AirLinx remote monitoring. This system allows users to track operational data, temperature levels, and maintenance needs in real time.

How to integrate an electric compressor on the job site

Switching from diesel to electric requires some adapting, but the transition is easier than expected. The key to seamless integration is ensuring the job site has the necessary infrastructure. 

On job sites requiring high-capacity electric equipment, such as the Sullair E425H, an electric drop refers to the dedicated infrastructure necessary to supply consistent, 480V power directly to the unit. This configuration typically consists of a fused disconnect switch, with a minimum rating of 200 amps, to ensure safe isolation and control of the power feed. Power is delivered via four 4/0 gauge cables — three phase lines and one ground — capable of handling the electrical load necessary for continuous compressor operation. Termination is achieved through Camlock connectors, which allow for a rapid, secure connection to the electrical source. Electric drops can be configured to draw from shore power, temporary distribution panels, or industrial-grade generators, with the primary objective being to maintain a stable and reliable power supply that meets the operational requirements of field-deployed electric air compressors.

While generators provide a workaround for remote sites without a power grid, their use may reduce some of the emissions benefits associated with an electric model. "For customers already using electric equipment, integrating the E425H is seamless," notes Cole. "However, for job sites that are primarily diesel-driven, it may require additional electrical set-up."

The swing-out cooler design of the E425H gives technicians easy access during maintenance.

Power stability and startup challenges

Power stability is one of the primary concerns when integrating electric compressors into industrial and construction settings where voltage fluctuations and power surges are common. To address this challenge, the E425H utilizes a solid-state starter, which reduces inrush current and ensures a gradual and controlled start-up. This boosts the reliability of power connections to prevent unnecessary wear on electrical components, distinguishing it from traditional variable speed drives, which can be vulnerable to unstable power conditions in field applications.

Unlike traditional stationary compressors, which often take five to ten hours to install and configure, the E425H is designed for rapid deployment. With set-up times as short as 15 to 30 minutes, this efficiency is made possible through camlock connections, which offer a secure and standardized method for quickly linking the compressor to the site's electrical system.

Another key design consideration is the two-inch air supply connection, which has been positioned away from the operator to enhance safety during installation. This adjustment reduces exposure to potential hazards and improves accessibility for maintenance and adjustments in the field.

The rental advantage 

The rental industry is a key sector that can benefit from the E425H's electric advantage. Lower maintenance costs and increased machine uptime translate directly into higher profitability. Unlike diesel compressors that require frequent refuelling and oil changes, the E425H's electric motor significantly reduces servicing needs, keeping machines available for rent more often.

The standard Sullair AirLinx feature is particularly beneficial for rental companies. This tool enables better fleet management, prevents unexpected failures, and ensures optimal machine utilization. "Rental houses can track machine location, monitor air pressure, and schedule maintenance remotely," says Cole.

Perhaps the most compelling advantage for rental businesses is the E425H's broad application range. The versatility of this machine ensures high utilization rates, making it a sound investment for rental fleets across many industries. "Rental businesses will see a strong return on investment with the E425H due to lower fuel costs, longer run cycles, and reduced maintenance," says Ohlinger.

Plans for more electric models

With increasing regulatory pressure on emissions and the global push for more sustainable solutions, the market is shifting toward electric-powered equipment. Hitachi Global Air Power is embracing this transformation, laying the groundwork for an expanded portfolio of electric compressors with the launch of the E425H. Plans for larger models like the E1600 and oil-free electric compressors are already in the pipeline.

"We have certain sustainability goals, including being carbon neutral throughout our value chain by 2050. Everything we're designing and building is for maximum efficiency and also for second and third lives where possible. So it's part of our engineering and innovation centre to build highly efficient, next-generation products to meet those goals and, more importantly, to help our customers meet those goals. We called it the new era of innovation with E1035, and it's just a new way of thinking and a new way of being customer forward and uber-focused on those sustainability goals that we all have."

"Diesel compressors will still play a role, but the shift toward electric is inevitable," says Cole. "The E425H is just the beginning of a broader move toward cleaner, quieter, and more efficient air compression solutions."

A smart investment

Combining sustainability, advanced technology, and reduced operating costs, the Sullair E425H offers a compelling alternative to diesel-powered units without sacrificing performance. A smart investment for contractors, rental companies, and industrial operators, the E425H represents one of the latest developments in portable air compression technology as many industries shift toward increased electrification. 

Company info

3700 East Michigan Blvd
Michigan City, IN
US, 46360

Website:
sullair.com

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