Jorc Industrial, LLC

Jorc is an independent manufacturer of products that are used to remove condensation from a compressed air system. Their experience in this business has led to a unique approach to solving the problems associated with compressor condensation.

The company has been successful because they deliver value to the customer by providing quality products at affordable prices. Our research found that they are able to combine technology and common sense to create reliable drains with practical features.
 

Smart Guard Drain

This special drain makes it possible for you to manage the condensation in your compressed air system without wasting compressed air. It has several exclusive benefits that eliminate the common problems caused by compressor condensate and the shortcomings of existing drains. These include the following:

The Smart Guard is the only drain to use radio wave signals and a special transducer to measure the presence of condensate. It opens the valve when condensate is present and has a safety setting that closes the valve before wasting compressed air.  The Smart Guard measures for condensation, volumetrically, 50 times per second. This continuous monitoring makes it possible for fast discharge of up to 20 gallons an hour for a 100 psi system, 30 gallons an hour for a 230 psi system. The large dumping capacity makes it possible for you to use this drain in most applications which eliminates the need for multiples sizes and types of drains. The Smart Guard is the only drain with a clear bowl so you can easily monitor the performance of the drain. This means you can see the cycling of the drain and investigate if the bowl stays full of condensate. The Smart Guard is the only drain without moving parts or sensors in the condensation. This eliminates maintenance. The Smart Guard uses a large orifice (4.5 millimeters) for the discharge of the condensation. This makes it possible for the drain to handle the larger contaminants often found in condensation without the constant clogging.

The Smart Guard can handle the condensation produced by the majority of compressed air systems used in industrial plants. You can simplify the operation by installing one on all drain points. This includes the aftercooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping.

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Potential Savings

The Smart Guard will quickly pay for itself when you replace your existing drains. The following explains:

• The Smart Guard is sold for less than $400! This is about 50% less than you will pay for the automatic (zero air loss) drains sold by the brand names in this industry. In fact, the price is compatible with what you would pay for some timer and float operated drains.

• Another area for saving money is the ability to recover energy costs and money previously spent on drain maintenance. Other drains will cause you to spend time and money to monitor and maintain and, in most cases, will waste compressed air. See Condensation Facts for more details on the shortcomings of other drains.

• Savings will also come from the elimination of condensation in your compressed air system. A consistent supply of dry air will reduce the equipment problems that lead to production downtime and poor quality.

A condensation drain should automatically remove condensate when it appears at the drain without wasting air or clogging. Also, it should be easy to monitor, affordable and capable of handling a large amount of condensate. The Smart Guard is the drain we have found that meets this criteria. 

Send an email to drain@compressorwise.com if you would like more information on this product. We will send you a picture, product specifications and details on the best way to purchase the Smart Guard.

Would you like more information on how to avoid problems with your condensation drains? 

“Case Study, Costly Drain Mistakes” explains the high cost of 3 installation mistakes that are made in many facilities. This report is exclusively available to subscribers of our newsletter. 

You can scroll down this page or use the Free Compressor Newsletter button to enter your subscription. Then, after you receive your Introductory Issue, simply request Issue 3 from Year 2002. 

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Other Products

Jorc has an extensive group of products that can handle any condensation related problem with prices that will save you money. The following are a few examples:

Air Saver

A compressor that has its own receiver tank is a familiar sight in industrial plants and manufacturing facilities. There is a hidden opportunity for energy savings with many of these machines. There is a potential for waste that is associated with these compressors when they do not operate 24 hours a day. This could be because the air use equipment is not operated around the clock or because the plant shuts down at the end of each day. The air that is stored in the tank can leak out through the piping system (from the tank to the point of air use) when the equipment is turned off for the day. This is a direct waste of the energy that was used to produce the compressed air.  If you have this situation in your facility, we would suggest that you install an automated valve and save a tank of air a day. Our research has found that the Air Saver has proven to be a good solution to this problem. A micro processor provides reliable operation of a motorized ball valve in the Air Saver. The controls are very user friendly which makes it possible to program the valve to open and close at specific times. The Air Saver is installed on the air piping that comes out of a receiver tank. It can be programmed to automatically open just prior to the start of a work shift and close just after the end of the work shift. This improvement has a very fast payback because it saves a tank of air a day and because of the low price of the Air Saver. This product is available in 2 sizes, so it can be installed easily on 1” or 2” pipe.  Send an email to airsaver@compressorwise.com if you would like more information on this product. We will send you a picture, product specifications and details on the best way to purchase the Air Saver.

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Smart Guard Pro

The Smart Guard Pro was designed for applications that require a larger drain capacity. It can handle 40 gallons an hour for a 100 psi system, 60 gallons an hour for a 230 psi system.  The Smart Guard Pro uses the same technology as the Smart Guard, so it has the same benefits – except for one. The Smart Guard Pro does not have a clear bowl to monitor the condensate activity.  Send an email to otherdrains@compressorwise.com with your question about the Smart Guard Pro. We will send you details on the best way to purchase this product.

MAG 11 Filter Drain

The MAG 11 was specifically designed for draining the filters that are used in a compressed air system.  An internal magnetic force provides power for the automatic draining valve. This gives you a zero air loss drain that does not require electricity.  Send an email to otherdrains@compressorwise.com with your question about the MAG 11 Filter Drain. We will send you details on the best way to purchase this product.

TEC 44

The TEC 44 was designed to drain the applications with large contaminants in the condensation. This includes systems with heavy rust and scale in the air piping as well as drain locations associated with deliquescent dryers.  The TEC 44 is a timer drain with a motorized ball valve that crushes its way through heavy duty contaminates. It has a micro processor, easy touch buttons for adjusting cycles and a battery for power failure back up.  Send an email to otherdrains@compressorwise.com with your question about the TEC 44. We will send you details on the best way to purchase this product.

Combo Drain

The Combo Drain is a timer drain that was designed for those customers that are not concerned about the energy cost of the air lost during drain cycles. It is mass produced with some unique benefits over the low priced timer drains on the market.  The Combo Drain has a larger discharge orifice (4.0 millimeters) than the similar drains sold by the brand names in this industry. It also has an integrated ball valve strainer. This protects the drain from large contaminates, and simplifies drain maintenance.  Send an email to otherdrains@compressorwise.com with your question about the Combo Drain. We will send you details on the best way to purchase this product.

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Condensation Facts

Condensation is the moisture that drops out of an air flow as it cools. The condensation in a compressed air system is a constant threat to cause expensive problems. The following are a few examples:

• Moisture washes lubrication from air tools and production equipment causing downtime and maintenance.
• An inconsistent supply of dry air causes production quality problems.
• Excessive rust and scale often forms in the air distribution system.
• Water can back up into the compressor and wreck the machinery.
• Air dryers can become overloaded.
• In-line filters can be destroyed.

The problems get worse if you operate lubed reciprocating or oil flooded rotary screw compressors – which is just about everyone. Compressor oil makes its way into the distribution system with the compressed air. The mixture of oil, water, dirt and heat tends to build up a sludge that will ultimately jam or clog production equipment, air tools and drains.

The situation is further complicated by climate and seasonal weather changes. This is because the amount of condensation generated will change according to changes in the temperature and the relative humidity of the inlet air. 

Consider that a 200 horse power compressor operating in a climate of 60 degrees F with 40% relative humidity will generate approximately 50 gallons of condensate a day. However, that same compressor operating in a climate of 90 degrees F with 70% relative humidity will generate approximately 260 gallons of condensate a day.

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The typical compressed air system is designed to remove condensation at strategic locations. This means there are drains at the aftercooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping. The following explains the shortcomings of the drains being used in industrial plants.

Manual Drains

These drains are valves that have to be opened manually to dump the condensation. Judging how often and when to drain each point manually is a complicated process. 

Some operators solve this problem by leaving the valve partly open at all times. This constantly drains the condensation and wastes compressed air in the process.

The energy cost to produce compressed air will vary depending upon the KW power rate. However, even a small continual leak will waste several hundred dollars in annual energy costs. 

Float Operated Drains

These drains use a float mechanism in a housing to automate the dumping of the condensation. The outlet valve is controlled by a float that rises as the housing is filled with the condensate.

This style of drain has a built in problem that is magnified in a lubricated compressed air system. The contaminants in the condensate will affect the performance of the internal components. The float mechanism tends to jam either in the open or closed position. 

Unless operators check the valve’s performance regularly, they will not realize that the drain has stopped working. Of course, if the float has stuck in the open position, the air blast will be audible.

There is no easy way to monitor the performance of this type of drain which increases the risks of condensation problems. In addition, the internal parts will require more maintenance because they are in constant contact with the condensation.

Timer Drains

These drains utilize an electronic timer to activate a valve that dumps the condensation. These drains are inexpensive and popular because many vendors who make, package or service air equipment include timer drains with their products.

You can adjust the drain cycles by setting the number of cycles per hour and the length of time the valve will stay open during each cycle. The idea is to set the timer for a long enough period to completely drain the condensation without setting it long enough to waste compressed air. 

This means that the settings will have to be adjusted to compensate for climate and seasonal changes. It requires considerable time, manpower and expertise to successfully manage this process. 

The reality is that many timer drains are operated at the initial factory settings. This practice will waste compressed air every cycle.

Some operators fear the consequences of too short an open time. They will set the open time to the longest setting and select a frequent cycle setting to make sure that the system drains completely which will waste compressed air every cycle.

The problem with timer drains is that they waste air every cycle unless perfectly set to match current conditions. In addition, the compressor controls will respond to the loss of air by loading the compressor to fill what is really an artificial demand for compressed air. 

Electronic Sensor Drains

These drains are very expensive in comparison to the other types of drains. They have electronic sensors monitoring the level of condensation within a housing. 

One sensor signals a valve to dump the condensate when the housing is full of condensation. Another signals the outlet valve to close before completely draining the condensate to avoid wasting air.

The housing makes it difficult to monitor the performance of the drain. In addition, it possible for foam to develop within the housing. This can cause the sensor to detect condensation which activates false signals that will lead to wasting compressed air and over working the components.

The sensing devices are in constant contact with the contaminants found in compressor condensation. This will damage the reliability of the drain and increase maintenance.

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Frequently Asked Questions

Why are Jorc drains priced so much lower?

Their philosophy is to deliver value to their customers. They believe this is best accomplished by providing an economical price on drains that work. This makes it possible for anyone to afford the top products that help manage compressor condensation.

Why does Jorc make timer drains?

Saving energy is not the top priority for everyone. In those cases, they want to provide the option of a timer drains with affordable prices.

What is the purpose of installing a strainer before drains?

A strainer is designed to keep the largest contaminants from reaching the condensation drain. They are also used to redirect the condensation when they have to do maintenance on a drain. This product is also known as “Y Strainers” and “Ball Valve Strainers”. 

Does Jorc recommend strainers be used with their drains?

A strainer is not required when using a Jorc drain. The orifice in their valves are larger than those used by the brand names in this industry. 

Why do drains with large ˝” connections clog?

It is not the size of the connection but the size of the orifice inside the valve that determines the size of the drain outlet. A drain with a larger outlet will be less likely to clog.

What is the best way to make sure a drain is working?

Install a manual valve, ahead of the condensation drain, which can be opened to see if water is not being drained. This also makes it easier to do maintenance on drains. (see Drain Piping Tips)

What maintenance is required for the Smart Guard?

The Smart Guard Drain was designed with a large orifice and that will keep maintenance to a minimum. Jorc recommends that the inside of the monitoring bowl be cleaned a couple of times a year, especially if the compressors are lubricated. This must be done without the use of solvents which are harmful to the clear Lexan bowl.

What can be used to handle applications with more than 20 gallons of condensation each hour?

The larger version of the Smart Guard is called the Smart Guard Pro, and it handles 40 gallons an hour. It was designed for applications, such as centrifugal compressors, that generate large amounts of condensation. 

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Drain Piping Tips

Selecting the right drain for the application is only half of the solution. The other half is avoiding mistakes during the installation. 

Installation mistakes are very common, and will prevent a drain from effectively removing the liquids. 

Send an email to drainpiping@compressorwise.com for an illustration with piping tips. 

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Contact Us

Jorc has proven the ability to deliver unique products at remarkable prices. This gives you the power to solve the problems caused by compressor condensation and save money in the process.

Send an email to drain@compressorwise.com if you have a question or would like additional information on condensation drains.