Air Compressor Buying Guide: How to Choose an Air Compressor

Welcome to our guide for buying an air compressor! Whether you're a DIY enthusiast or a seasoned industrial professional, choosing the right air compressor can be a daunting task. With so many options available, it's easy to feel overwhelmed.

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But don't worry, we're here to help you navigate through the complexities and make an informed decision. In this guide, we'll cover everything from air compressor sizes to noise levels, ensuring you have all the information you need to make the best choice.

One of the first questions you should ask yourself is whether you need an air compressor for home use or industrial applications. The requirements for these two scenarios can be vastly different.

For home use, air compressors are generally smaller, more portable, and less powerful. They are perfect for tasks like inflating tires, powering small air tools, and even spray painting. These compressors usually operate on a single-phase power supply and are designed to be user-friendly.

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Industrial air compressors, on the other hand, are built for heavy-duty applications. They are larger, more powerful, and can handle continuous operation. These compressors often require a three-phase power supply and are designed to meet the high demands of industrial environments. They are ideal for powering large machinery, pneumatic tools, and other industrial equipment.

If you're using a single-phase power supply, your options are somewhat limited. Single-phase power can typically support compressors with up to 3 HP (2.2 KW). These compressors are suitable for most home and light industrial applications.

Reciprocating compressors, also known as piston compressors, use pistons driven by a crankshaft to deliver air at high pressure. These compressors are typically used for applications requiring high pressure and lower volumes of air. They are known for their durability and ability to handle intermittent duty cycles, making them ideal for smaller operations and workshops.

Rotary screw compressors use two interlocking helical screws (rotors) to compress air. As the screws rotate, they reduce the volume of the air, increasing its pressure. These compressors are designed for continuous operation and are commonly used in industrial applications requiring a constant supply of compressed air. They are known for their efficiency, reliability, and low maintenance requirements.

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So here’s whats going on (cause I’m trying really hard not to hyjack someone elses thread). Back in /’ish I got a California Air Tools 2 HP/ 10 Gallin oiless air compressor. Seems like back during that time, Calf. Air Tools was on the “cutting edge” of the quite air compressors. In I was moving cross country, trying to downsize and sold that little compressor and I’ve regretted it ever since. It was great for me and fit my needs (for the most part) although admittedly if I had to do it again I’d go a little bigger.

So since I bought that last compressor, it seems like the oilless air compressors have come a long way; more longevity, more manufactures jumping on the quite oillless bandwagon. Now lets be honest, cause I know someone will come in here pounding on their chest saying oiled is the way to go and oillness are throw away- I get it. There is an arument there. But honestly, all I do it body and paint on a small scale, usually using a LVLP gun, and these little compressors work great for me and fit my needs.

But in , given the leeps and bounds in this segment in since when I purchased my last one- who is making the best 20 to 30 gallon quite oillness air compressors out today?

Looking for recommendations if you have them. Still CAT, but they are spendy, and you can get a pretty good imitation for less money. Harbor Freight's Fortress line is a pretty good bargain, especially with a coupon.

I really like the looks of their horizontal model, but this vertical model has a little more output and more air storage. They don't make quite as much flow as the 2hp CAT models, but they have higher tank pressures so you've got more air on demand for a given tank volume.

If you want to splash for the CAT, their 2HP models in your choice of tank configuration are pretty sweet. Their newest thing are their Continuous run models.

They advertise up to 8 hours of continuous use at 90 psi. They make slightly less output and are a little louder, but it might be worth it for you.

Edit: User @Hatsuwr created this spreadsheet comparing lots of the available models if you want to comb through the specs.

Still CAT, but they are spendy, and you can get a pretty good imitation for less money. Harbor Freight's Fortress line is a pretty good bargain, especially with a coupon.

I really like the looks of their horizontal model, but this vertical model has a little more output and more air storage. They don't make quite as much flow as the 2hp CAT models, but they have higher tank pressures so you've got more air on demand for a given tank volume.

If you want to splash for the CAT, their 2HP models in your choice of tank configuration are pretty sweet. Their newest thing are their Continuous run models.

They advertise up to 8 hours of continuous use at 90 psi. They make slightly less output and are a little louder, but it might be worth it for you.

That is advertised at 77 db. FWIW I just measured my older belt driven Crapsman and it was around 65 db standing right next to it. 5' away it was < 60 db.

That is advertised at 77 db. FWIW I just measured my older belt driven Crapsman and it was around 65 db standing right next to it. 5' away it was < 60 db.

The Fortress is rated at 69, the "standard" CAT is rated at 70, and yes, the continuous model is rated at 77, which is why I said it was louder.

Regarding your old Craftsman, congrats on getting such an uncharacteristically quiet reciprocating compressor, which happens to rival even the leading scroll and rotary screw compressors on the market.

That said, are you sure your observations might not be due to a difference in testing methodology/equipment?

The Fortress is rated at 69, the "standard" CAT is rated at 70, and yes, the continuous model is rated at 77, which is why I said it was louder.

Regarding your old Craftsman, congrats on getting such an uncharacteristically quiet reciprocating compressor, which happens to rival even the leading scroll and rotary screw compressors on the market.

That said, are you sure your observations might not be due to a difference in testing methodology/equipment?

Oh I'm sure, I used a cell . Quick google says scrolls go down to about 50 db so that is significantly quieter than the 65 I measured mine at.

I noticed that CAT now has a 2 stage 20 gallon 1.5 Hp model, thats very interesting . . . anyone know anything about them? Black Friday is coming up, thats the date I plan on pulling the trigger in either event I go with.

California Air Tools 20 Gal. 1.5 HP Ultra Quiet High Pressure Electric Air Compressor with Auto Drain Valve HPAD - The Home Depot

Control the pressure to your convenient level by choosing this California Air Tools California Air Tools Ultra Quiet High Pressure Electric Air Compressor with Auto Drain Valve.

I hadn't heard about them but it is interesting. I'm sure it will be useful for someone who needs max pressure, but for my part, I would rather have the flow than the max psi.

I hadn't heard about them but it is interesting. I'm sure it will be useful for someone who needs max pressure, but for my part, I would rather have the flow than the max psi.

Thats a great point, I’ll have to consider than. I just got excited about having a 2 stage compressor, wasn’t away I could get that in this size at this price point. That was the only down fall of my last one with a single stage 10 gallon tank. I was doing some sand blasting and it realy struggled. Not something I do on the regular, but I’d still like to have the option- sort of thing.

Oilless compressors have been around for decades. They have also served most homeowners just fine for decades - albeit loudly. Just heavy use over years wears them out. I think it still stands to be seen if the new generation of "quiet" oilless compressors will be durable and have better longevity.
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They don't. They achieve quiteness by having lots of plastic parts, which wear out, particularly if run hard for long periods. But they're super quiet, which makes working with them much more pleasant. And there are lots of environments where that makes up for shorter life, or doesn't matter -- i'm not going to wear mine out in my lifetime, and on construction sites it'll get stolen or fall off a second floor before it wears out.

They don't. They achieve quiteness by having lots of plastic parts, which wear out, particularly if run hard for long periods. But they're super quiet, which makes working with them much more pleasant. And there are lots of environments where that makes up for shorter life, or doesn't matter -- i'm not going to wear mine out in my lifetime, and on construction sites it'll get stolen or fall off a second floor before it wears out.

Is this true, plastic parts?

Any build diagrams or info? All I know is I beat the hell out of my old one and it just kept coming back for more. I’ve been using the hell out the new one, and I freaking love it. My wife keeps draging home all wood/ free furniture and having me repaint and refinish them. Got to play with my new spray gun too. This 20 gallon model doesn’t refill as frequently as my 10 gallon did, so I could see less wear and tear on this one. Got my dual airline system set up with a 50 foot hose reel.

Very happy I punted that 60 gal Dewalt for this one.

Now lets be honest, cause I know someone will come in here pounding on their chest saying oiled is the way to go and oilless are throw away- I get it. There is an argument there. But honestly, all I do it body and paint on a small scale, usually using a LVLP gun, and these little compressors work great for me and fit my needs.

There are oilless compressors not yet even built that will fail long before my mid-s Devilbiss-built Craftsman fails - and it's starting with a 40 year disadvantage. It's a portable hot dog style, rated 4 hp and 7.7 SCFM @ 90 psi, so mid sized. Honestly, with an oiled compressor pump, twin cylinders, belt drive, and rpm motor, it's not all that noisy for this much capacity. And the cast iron compressor pumps are even quieter than this aluminum one.

I've changed the motor bearings on it; other than that, only oil changes.

I think the jury is out on the longevity of the new generation of oilless, but I'm willing to wait and see. Meanwhile, this Craftsman will likely outlive me.

I think the jury is out on the longevity of the new generation of oilless, but I'm willing to wait and see. Meanwhile, this Craftsman will likely outlive me.

I dunno. I'm going go out on a limb and say that "oil vs oilless" is a red herring. The quality of the rest of the assembly is what matters. It's super easy to swap a cylinder and piston on an oilless. Assuming you can get the parts.

What killed my oilless Craftsman compressor after 15 years was the vicious cycle of other failures after I swapped the cylinder/piston. Parts were not cheap relative to the cost of the compressor. I eventually got fed up with it.... and the day I was moving the garage supplies 250 miles to the new house, it wouldn't fill past 90psi.... and the U-Haul was already stuffed.... so I gave it away.

I now have a big oiled, 2-stage CH. New garage conveniently has insane electrical in place. I like the "thup-thup-thup" of the new compressor, but my old oilless Craftsman wasn't much louder.

-Ryan

It's super easy to swap a cylinder and piston on an oilless. Assuming you can get the parts.

That's also the issue with my Craftsman. I can get the head gasket and reed valves for it, but not much else - hence, I watch the oil level carefully.

I note that the pancake style oilless now have an expiration date on the air storage tank - something that would keep me from buying one of those. I'm guessing the thinned the metal on these compared to our "classic" ASME oiled compressors is such that it's best to toss them rather than repair the piston and diaphragm.

That's also the issue with my Craftsman. I can get the head gasket and reed valves for it, but not much else - hence, I watch the oil level carefully.

I note that the pancake style oilless now have an expiration date on the air storage tank - something that would keep me from buying one of those. I'm guessing the thinned the metal on these compared to our "classic" ASME oiled compressors is such that it's best to toss them rather than repair the piston and diaphragm.

Apples and oranges. Many of the forty year old consumer grade belt driven compressors are scrapped because the tanks failed. Only the commercial grade compressors had ASME certified tanks, and, when new, those compressors were priced out of the homeowner market.

Do a search here and tally up the threads asking about welding up the tank of an otherwise “perfectly good” compressor.

The expiration date on tanks is a bit of self preservation for the manufacturer more so than an indicator that tanks on low cost compressors have been downgraded.

They’ve always been marginal. That goes with making an affordable tool.

And don’t get on the “cry once” bandwagon. My .02 cents on the oiled vs. oilless . . .

I think there is a place for both honestly. I have a buddy who has to own top of the line “enter item here” but all his stuff/ tools just sit with minimal use. If I was in a professional shop, like the old aircraft painting shop I used to work at, oiled would be the way to go- no question. But for my garage DIY purposes, when I use it- I use it. But I’m not using it everyday. So I have zero concerns going oilless and have been using them for almost 10 years with zero issues. But I will admit I’ve only used/ owned the oilless compressors from California Air Tools; so I cannot speak to any other brands.

Back on the topic of compressors you own, I forgot to mention the one I have in race trailer. My Metabo “The Tank” is their upgraded version of their standard model. Its also been fantastic! Its a little noisey, but it goes into use trackside so noise isn’t factor there.

Many of the forty year old consumer grade belt driven compressors are scrapped because the tanks failed. Only the commercial grade compressors had ASME certified tanks, and, when new, those compressors were priced out of the homeowner market.

Oregon required that units sold here had ASME certification, even for homeowners. It did add a small premium to the price, but in the long run it's proven to be well-invested, I think.

Sears' catalog page below, FWIW - you can see the difference between ASME and non-ASME units under the "Catalog Number" column. ASME certification added $20 to the price of mine, on the second-to-last line. It also added 5 lb. of weight, which I presume is for a thicker tank. I didn't consider the $20 a burden: