Episode 21: Repair or Replace?

Jason Reed

Alright, welcome back to The Big Dog Podcast! I’m Jason Reed, here with Lisa Saunders. Today’s episode—Repair or Replace?—is for every facility manager who’s ever stared down a cranky compressor and thought, “Now what?”

Lisa Saunders

Hey everyone! This is one of those questions that comes up way more often than people think. You’ve got a rotary screw compressor that’s been running for years, and suddenly it’s making weird noises, or the pressure’s all over the place. So, do you fix it, or is it time to say goodbye?

Jason Reed

Yeah, and look, most folks wanna repair first. It’s just how we’re wired—nobody wants to toss out a big piece of equipment if you can squeeze a few more years out of it. But sometimes, you’re just throwing good money after bad.

Lisa Saunders

Exactly. There are some clear signs that repair makes sense. Like, if your compressor’s still under warranty, or it’s a first-time failure, or honestly, if it’s just a simple fix. And don’t forget the logistics—sometimes replacing a compressor means tearing out walls or, I don’t know, bringing in a crane. That’s a headache nobody wants.

Jason Reed

Yeah, I’ve seen places where swapping out a unit meant shutting down half the plant. If parts are easy to get and the machine’s not ancient, repair’s usually the move. But—big but here—if you’re dealing with the same breakdowns over and over, or the thing’s more than a decade old, you gotta start thinking replacement.

Lisa Saunders

And don’t forget efficiency. The older your compressor, the more you’re probably paying in energy. I mean, electricity is, what, like 76% of the total cost of ownership for a compressor? That’s huge. If your unit’s not meeting current standards, or it’s just not sized right for your needs anymore, replacement can actually save you money in the long run.

Jason Reed

Yeah, and sometimes the finance folks are actually on your side for once. If you can depreciate a new unit or keep the old one as backup, it’s worth a look. But, Lisa, you had a story about this from your first plant job, right?

Lisa Saunders

Oh, yeah. So, my first year on the job, we had this ten-year-old compressor that started acting up—pressure drops, weird noises, the works. Everyone wanted to patch it up, but the thing was out of warranty, and parts were getting hard to find. We debated for days, but finally decided to replace it. Honestly, it saved us weeks of downtime. If we’d kept repairing, we’d have been chasing problems all year. Sometimes you just have to make the tough call.

Jason Reed

That’s the thing—sometimes you gotta rip off the Band-Aid. Alright, let’s talk about why sizing and new tech matter so much when you’re thinking about upgrading.

Jason Reed

So, here’s the deal with sizing. If your compressor’s too small, it’s running nonstop, wearing itself out, and you’re still not getting enough air. Too big, and you’re wasting energy, paying for capacity you don’t need, and probably dealing with more maintenance than you should. It’s like—well, I was gonna say it’s like wearing shoes that don’t fit, but that’s a terrible analogy. You get what I mean.

Lisa Saunders

No, I think that works! And it’s not just about the size, it’s about how your needs have changed. Maybe you’ve added new tools, or taken some away. If your compressor was sized for a different setup, you’re either starving your system or bleeding money. And with new tech out there—like variable-speed drives and high-efficiency motors—you can get way more out of your system for less energy.

Jason Reed

Yeah, variable-speed drives are a game changer. I mean, older belt-drive models just can’t compete. I worked with a Midwest manufacturer last year—well, I say “worked with,” but really I just got called in to look at their bills. They swapped out a fifteen-year-old unit for a new VSD model, and their energy costs dropped, like, overnight. Not saying that happens every time, but the payback period can be way shorter than people think.

Lisa Saunders

And it’s not just about the money, either. Newer compressors are built with tighter tolerances, better controls, and they’re just more reliable. Less downtime, fewer headaches. Plus, if you’re thinking about sustainability, using less energy is always a win.

Jason Reed

Right, and if you’re still on the fence, talk to your local air compressor expert. They see this stuff every day and can help you figure out if an upgrade makes sense for your setup. But let’s say you do decide to replace—what do you do with the old unit? That’s a whole other can of worms.

Lisa Saunders

Yeah, so, once you’ve made the call to replace, you can’t just haul the old compressor to the dumpster. There’s a right way to do it, and it starts with checking your local and state regulations. Some places are really strict about how you handle oil, condensate, electronics, and all those metals inside.

Jason Reed

Yeah, you gotta drain the oil—every compressor’s got it, even so-called “oil-free” ones use oil somewhere. And that condensate? It’s not just water, it can have oil and other junk in it, so you can’t just dump it down the drain. Gotta follow the rules, or you’re asking for trouble.

Lisa Saunders

And don’t forget the electronics. Older controls can have stuff like lead or mercury, and in a lot of states, you’re required to recycle them. Same goes for the filters and separators—they can have hazardous materials, so they need to be handled properly.

Jason Reed

Once you’ve stripped out the liquids and electronics, you’re left with a pile of metal—aluminum, iron, copper, nickel, stainless steel. Most of that can be recycled, which is way better than sending it to a landfill. Plus, you might even get a little money back for the scrap.

Lisa Saunders

And honestly, recycling isn’t just good for the environment, it can save you on disposal costs, too. I remember a distributor we worked with—he helped a client recycle their old compressor, and not only did they avoid landfill fees, but they actually got a rebate from the recycler. Total win-win.

Jason Reed

If you’re not sure where to start, reach out to your local Kaishan distributor. They know the ins and outs of the regulations, and they can walk you through the whole process—repair, replace, recycle, whatever you need. No shame in asking for help.

Lisa Saunders

Absolutely. These decisions can get complicated, but you don’t have to go it alone. That’s what the experts are for. And hey, if you’re listening and you’ve got a story about a tough repair-or-replace call, we’d love to hear it—send it our way!

Jason Reed

Alright, that’s gonna do it for this episode of The Big Dog Podcast. Next time, we’ll dig into some of the latest trends in compressed air tech—so stay tuned. Lisa, always a pleasure.

Lisa Saunders

Thanks, Jason. And thanks to everyone for listening. Take care, and we’ll catch you next time.

Jason Reed

See ya, folks.