150HP / 110kW / 5bar / 6.4–27.5 m³/min Low‑Pressure Screw for Air‑Jet Loom — Selection, Sizing & Quotation Guide

For air‑jet weaving, 5bar is a low‑pressure, high‑volume duty. A 110kW/150HP PM‑VSD low‑pressure screw can be right for mid‑size weaving sections, but the “6.4–27.5 m³/min” range must be interpreted correctly: 27.5 m³/min is near full‑load at 5bar for some low‑pressure/dual‑stage/PM models, while 6.4 m³/min is more like VSD part‑load lower end. Sizing should always start from loom consumption, not from the catalog max.

1. What 110kW/5bar low‑pressure screw realistically delivers

Supplier samples for 110kW low‑pressure screws at 5bar:

• Single‑stage oil‑lubricated low‑pressure screw: ~23.5 m³/min @5bar (Adekom KE110L‑5)

• PM VSD low‑pressure screw: 10.65–26.2 m³/min variable @5bar (LIUTECH LU110‑5 IVR), fixed 25.9 @5bar

• Dual‑stage PM VSD: 27.4 m³/min @5bar (Jufeng JF‑150AHV 110kW) ; another 110kW PM dual‑stage lists 27.5 m³/min @5bar

• 110kW two‑stage electric low‑pressure sample: 28.5 m³/min @5bar

• Generic 110kW/5bar low‑pressure tables: 22.0–27.5 m³/min depending airend/rotor/control

Takeaway: for 110kW at 5bar, plan around 23–28 m³/min FAD​ for a dedicated low‑pressure machine, but request ISO 1217 FAD at 5bar, 35°C/1bar a inlet, and confirm whether the number is displacement, FAD, or VSD maximum. A 7–8bar standard screw derated to 5bar via regulator is not a low‑pressure machine and wastes energy.

2. Air‑jet loom demand — how many looms per 110kW unit

Loom air use depends on reed width, fabric weight, yarn, pick rate and nozzle timing:

• General modern air‑jet loom: commonly 0.8–2.5 m³/min at 5–6bar​ per machine in vendor/industry guidance

• Specific research weave case: total ~0.74 m³/min standard‑air (computed) / ~0.81 m³/min actual for one configured loom style — useful for nozzle‑level study, not for general mill sizing

• Mill rule‑of‑thumb for budgeting:

  • Light cotton/poly, narrow width, moderate RPM: 0.8–1.2 m³/min/loom

  • Standard 190–230cm cotton/poly shirting/sheeting: 1.0–1.6 m³/min/loom

  • Heavy twill/denim/wide/high RPM: 1.6–2.5+ m³/min/loom

Approximate loom count per single 110kW/5bar screw:

*Before system margin, leakage and dryer/filter pressure drop. For a real station use 10–20% leakage allowance and 10–15% production growth/spare.

Example: 20 looms × 1.4 m³/min = 28 m³/min average. A single 110kW low‑pressure screw at 27.5 may barely cover average with no margin; better specify 2× smaller VSD units or 1×110kW + 1×small trim/standby, depending on shift load.

For 50–100 looms, total demand can be 70–200+ m³/min ; single 110kW machines are no longer optimal—evaluate multi‑unit screw bank or low‑pressure centrifugal.

3. Pressure setpoint for air‑jet loom

• Main/relay nozzle supply header commonly 5–6bar in many mills; main nozzle pilot pressure may be 3–6bar depending loom make .

• Set compressor discharge slightly above required header: e.g., loom need 5bar at farthest loom → compressor 5.3–5.5bar, then account for aftercooler/dryer/filter/header drop. Avoid running 7–8bar and reducing at the loom—textile low‑pressure savings are significant; low‑pressure dedicated screws can reduce energy versus 7–8bar machines with downstream regulators .

• Keep header pressure stable: VSD screw holds tight band; fixed screw uses load/unload/throttle and needs larger receiver. Pressure variation across looms worsens weft insertion consistency .

4. Screw vs centrifugal for jet loom

Use the duty shape, not just total flow:

Low‑pressure oil screw (110kW PM/VSD)

• Good for variable shifts, multi‑fabric, frequent style changes, parallel expansion.

• Positive‑displacement: stable flow across pressure changes, easy multi‑unit parallel, no surge in normal modulation range.

• VSD matches part‑load; good where loom utilization swings by shift/season.

• Oil‑injected needs strong downstream treatment for textile air quality; at very low 5bar the oil‑separator delta and carryover behavior must be checked.

Low‑pressure centrifugal (oil‑free)

• Good for large, stable, single‑product weaving: many looms, steady 5–6bar, high total flow.

• Large single units, high efficiency, inherently oil‑free; some sources recommend centrifugal for large jet‑loom rooms with stable high flow , and note oil‑free air reduces solenoid/nozzle contamination issues .

• Surge/part‑load weakness: poor for highly variable demand unless combined with screw trim or inlet‑guide/variable‑speed controls.

• Rule‑of‑thumb crossover: screw often favorable below ~1500–2000 m³/h? No—above roughly 1500–2000 m³/min centrifugal becomes more economic in some guidance; for 40–55 m³/min screw vs centrifugal crossover is often quoted around 1500–2000 CFM/≈40–55 m³/min in general‑compressor comparisons, but textile low‑pressure centrifugal economics also depend on stability and oil‑free requirement . A 27.5 m³/min single 110kW screw is well within screw territory; only when total mill demand is much larger and stable should pure centrifugal be default.

Practical mill design: base load large centrifugal or several big low‑pressure screws + 1×VSD/small screw for trim and style changes.

5. Air quality for air‑jet loom

Jet looms are sensitive to oil and water: moisture causes weft sticking/break/rust in nozzles; oil stains yarn, fouls solenoid valves and reed, shortens solenoid life .

Recommended train for 5bar weaving header:

1. Aftercooler → bulk moisture separator + auto drain.

2. Refrigerated or desiccant dryer depending humidity and loom requirement. Some guides recommend dry air with dew point below −20°C for air‑jet weaving ; high‑humidity mills may use desiccant, but final spec should follow loom OEM and local climate.

3. Filtration: coalescing for oil aerosol, particulate after dryer; if oil‑free compressor, still filter particles and (for desiccant) dust.

4. ISO 8573‑1 target: many textile guides use Class 2 or better for solids/water/oil ; premium/white fabric lines may tighten further. If solenoid/lint sensitivity is high, define solid class, dew point class and oil class separately rather than “clean air” marketing.

5. If using oil‑injected 110kW low‑pressure screw: specify large low‑pressure oil‑separator, <1–3mg/m³ or ppm‑equivalent outlet per OEM, point‑of‑use 0.01µm coalescing if needed; monitor oil carryover because low discharge pressure can change separator behavior.

6. If “no oil contact” is mandatory (white/technical/export fabric), evaluate oil‑free screw/centrifugal + desiccant instead of oil screw + filters.

6. 110kW low‑pressure package specification

For air‑jet duty, request:

• Airend: low‑pressure dedicated screw, single or two‑stage; large rotor/low speed for 5bar; not a 7–8bar airend with pressure cut. Dual‑stage 110kW samples at 5bar reach ~27–28 m³/min but verify efficiency vs single‑stage low‑pressure.

• Motor: 110kW PM IE4/IE5 or high‑efficiency AC, 3‑phase 380/400/415/440V 50/60Hz, IP55/IP54, F/H insulation, direct coupling.

• Drive: VSD/PM VSD preferred for weaving load variation; soft start, 5bar constant‑pressure band, turndown to ~25–30% flow. If catalog says 6.4–27.5, ask for VSD flow curve at 5bar, not only max.

• FAD: ISO 1217 at 5bar; also request 4/5/6bar points; specific power kWh/m³ at average mill load.

• Oil system: low‑pressure oil separator sized for 5bar, separator outlet ppm, oil spec, oil cooler, auto make‑up if offered.

• Cooling: air‑cooled for small/medium mill; water‑cooled if plant has cooling water or ambient >40°C/very humid. Textile guidance notes machine‑room <40°C and good ventilation for air‑cooled . Some 110kW low‑pressure units list 70–77 dB(A) ; confirm loaded noise at 1m.

• Receiver: central weaving station often 1–3 m³ for 110kW class, bigger for fixed‑speed multi‑unit; VSD can use smaller but loom surge/header stability may need more. Size from loom burst pattern and control response.

• Outlet/header: 110kW@5bar ~25–28 m³/min usually DN80–DN100 depending velocity; keep main ring low velocity (<8–10 m/s) to reduce drop .

• Controls: PLC/master controller for multi‑compressor, pressure/flow/dew point/kWh logging, leak alarm, remote Modbus.

• Dryer/filter: capacity matched to 5bar FAD, not to 7–8bar nameplate; desiccant PDP if required; auto drains.

7. Energy and station design notes

• Air‑jet weaving compressed air can be a major energy share; some textile sources put compressed‑air/air‑jet energy at 60–80% of loom electrical use and compressor station at 30%+ of mill energy . Low‑pressure dedicated machines, VSD, good dryers and leak control matter more than small price differences.

• Avoid 7–8bar screw + regulator for 5bar looms: low‑pressure dedicated screw can save substantial energy versus standard higher‑pressure machines throttled down .

• Leak program: ultrasonic survey, fix unions/solenoid/header; 10–20% unaccounted loss is common in old weaving rooms.

• Heat recovery: oil screw 5bar still rejects heat; if plant has process water/boiler feed make‑up, consider recovery only if payback fits; many weaving mills prioritize stable pressure and low dew point first.

• Spare/redundancy: continuous weaving hates downtime. For one 110kW serving critical looms, add trim/standby or design 2×50–60% VSD rather than 1×100%.

8. RFQ template — 110kW/150HP/5bar jet‑loom screw

Request in writing:

1. Type: low‑pressure oil screw / dual‑stage PM / oil‑free screw / centrifugal alternative. State if 5bar dedicated airend.

2. Power: 110kW/150HP; motor IE/PM grade; 380/400/415/440V 3‑ph; IP; insulation; direct/belt.

3. FAD: ISO 1217 at 4/5/6bar; VSD range 6.4–? m³/min at 5bar; displacement separately; specific power kWh/m³ at 5bar average load.

4. Pressure control: VSD constant pressure band; fixed‑speed load/unload; safety relief; min/max 5bar setpoint.

5. Oil separation: separator outlet ppm/mg at 5bar, separator life, oil spec, low‑pressure oil‑scavenge pump if offered.

6. Cooling: air/water; ambient range; aftercooler outlet temp; dryer type/PDP at 5bar FAD.

7. Air treatment: aftercooler, moisture separator, refrigerant/desiccant, filter microns, ISO 8573‑1 class guaranteed for weaving.

8. Receiver/header: recommended tank volume, outlet DN, max velocity, pressure drop budget.

9. Controls: master controller for N+1 looms, IoT, kWh/flow/dew‑point logging, alarms.

10. Noise/vibration: dB(A) at 1m loaded; foundation; anti‑vibration.

11. Certificates: CE/ISO 9001/1217 test sheet, PED/ASME tank, motor cert, energy label.

12. Commercial: EXW/FOB/CIF, lead time, spares (separator/filters/oil/valves/sensors), service intervals, warranty (airend/VSB/motor separate).

9. Sample quotation copy (engineering sales)

110kW / 150HP Low‑Pressure PM Screw Air Compressor for Air‑Jet Loom, 5bar

Dedicated low‑pressure rotary screw package for textile weaving mills. 110kW permanent‑magnet VSD motor, 5bar working pressure (4–6bar adjustable), FAD approximately 23–28 m³/min depending airend and control—request ISO 1217 at 5bar; VSD part‑load range quoted separately. Large low‑speed rotors, single or two‑stage low‑pressure airend, direct‑drive IE4/PM motor, air‑ or water‑cooled aftercooler, low‑pressure oil‑separation system and intelligent constant‑pressure controller for stable jet‑loom header. Suitable as single unit for small weaving sections or in multi‑unit/master‑controlled station for 20–100+ looms. Optional refrigerated or desiccant dryer, coalescing/particulate/carbon filtration to ISO 8573‑1 weaving class, central receiver and ring‑main design. Compared with 7–8bar screw plus regulator, dedicated 5bar low‑pressure screw reduces over‑compression and running cost.

Indicative specs: 110kW/150HP • 380–415V 3‑ph 50/60Hz • 5bar setpoint • FAD ~25.9–27.5 m³/min for selected low‑pressure/PM models, ~23.5 for some single‑stage 5bar units (confirm ISO 1217) • VSD 6.4–27.5 m³/min depending model/curve • DN80–DN100 outlet • air‑cooled ~70–77 dB(A) by model • auto drain/dryer/filtration optional • CE/ISO/PED, OEM voltage/tank/dryer customizable.

Replace FAD, VSD curve, noise, oil ppm and dryer PDP with factory test data; do not sell 27.5 as guaranteed for all 5bar duties.

10. Common mistakes

• Using 7–8bar screw at 5bar via reducer—wastes energy; use low‑pressure airend.

• Taking “27.5 m³/min max” as continuous supply for 20–30 looms without leakage/dryer margin.

• Ignoring oil carryover on jet looms—solenoids/nozzles/reeds foul; either oil‑free compressor or validated low‑ppm separation + fine coalescing.

• Under‑drying in humid weaving rooms—moisture causes weft defects; specify PDP by fabric/Climate, not “refrigerated only” by default.

• One big fixed‑speed 110kW for variable style mix—prefer VSD or N+1 VSD bank.

• Small header/high velocity—pressure drop across loom room causes uneven insertion; size ring main for low dp.

• No leak program—jet‑loom rooms lose substantial air through old solenoid/union leaks; savings from leak repair often exceed small compressor‑model differences.

If you give loom model/width/RPM/fabric type, number of machines, shifts, ambient humidity, existing header pressure and whether air must be oil‑free, I can calculate total FAD, recommend 1×110kW VSD vs 2×smaller vs centrifugal‑screw hybrid, tank size, dryer PDP and ISO 8573‑1 filter grades.