When installing new grain handling equipment, farmers today have more choices than ever. From bucket elevators to augers, conveyors, and grain pumps, the options are extensive. However, if a pneumatic air system is the right choice for your operation, one option stands out: Vari-Air air systems by JPS. Well-regarded throughout the industry, Vari-Air systems offer unmatched performance, efficiency, and reliability. In this post, we’ll explore when an air system is the best choice for moving your grain, what sets Vari-Air apart, and why we exclusively use them for the projects we design.
Is an Air System the Right Choice for Moving Your Grain?
Pneumatic conveyors, or air systems, provide an efficient method for moving dry grain from a specific inlet to various storage bins. The most common application involves connecting them to the discharge of a grain dryer or, in some cases, from a specific bin used as a surge bin to feed the air system. One limitation of air systems is capacity—they are an excellent option for capacities up to approximately 2,500 BPH. If you need to move grain faster than that, a bucket elevator or drag conveyor is likely a better option.
It’s important to note that air systems are designed for dry grain, not wet grain. They work best with corn, although they can also handle soybeans, oats, cracked corn, wheat, and other commodities. However, capacities may be significantly reduced when moving these alternative grains.
Addressing Historical Concerns About Air Systems
In the early years of air systems—before the affordability of pairing them with VFD controllers—they sometimes gained a bad reputation. Below are a few common concerns and how modern technology has addressed them:
- Grain Damage: Some older systems were tough on grain quality, particularly when installations were not done correctly. Proper installation and connections are critical. Additionally, older systems lacked pressure and speed regulation, meaning they pushed grain at the same speed regardless of how full the system was. With the introduction of VFD controllers, this issue has been resolved.
- Large Motors: Air systems typically require blower motors ranging from 15HP to 75HP. Previously, this was a challenge for single-phase power users who needed phase converters or soft starts. With modern VFD technology, large motors can now be efficiently run on single-phase power while adjusting to demand, reducing unnecessary energy consumption.
- Noise Levels: Older air systems were notoriously loud. While strategic placement, mufflers, and housing installations helped mitigate noise, modern Vari-Air systems are significantly quieter, making these additional measures less necessary.
Advantages of Air Systems Over Other Grain Handling Options
- No motors positioned in elevated areas, such as the top of a bucket elevator or bin peak, as required by augers and conveyors.
- More cost-effective initial investment compared to a bucket elevator, tower, and spouting.
- Straightforward and affordable expansion—simply add additional spouting and a few elbows to plumb to the next bin.
- Superior grain quality (as opposed to augers) when a JPS system is installed correctly.
- Flexible design to accommodate future bin locations and expansions.
- Enhanced safety with minimal moving parts and little to no maintenance required in elevated locations.
Advanced Variable Speed Technology
A standout feature of Vari-Air is its built-in variable speed capability. The system automatically adjusts speed based on air pressure, ensuring optimal efficiency. When more grain enters the system, Vari-Air increases speed to move it efficiently to storage bins. Conversely, when the dryer releases less grain into the airlock, the system slows down, reducing wear and preventing grain damage.
Vari-Air utilizes advanced variable frequency drive (VFD) technology, continuously adjusting motor speed to match air demand. This results in significant energy savings—studies indicate that businesses using VFD technology can reduce energy costs by up to 35% compared to traditional fixed-speed compressors. While the initial investment in a Vari-Air system may be higher than conventional alternatives, the long-term cost savings make it a highly cost-effective solution, particularly for industries with high usage, such as manufacturing, food processing, and agriculture.
Durability and Reduced Maintenance
Another key advantage of Vari-Air systems is their Tri-Lobe Blower, which operates at a lower RPM than twin-lobe systems. The engineering behind this design is so robust that, in the 14 years since its introduction, there has not been a single recorded failure. Compared to two-lobe blowers, which often struggle with fluctuating pressure, the Tri-Lobe Blower excels in handling varying pressure levels. This design results in:
- Reduced noise levels
- Smoother grain delivery
- Less wear and tear
- Longer system lifespan
Scalability and Adaptability
Whether for a small or medium-sized farm or a large grain handling facility, Vari-Air can be tailored to fit specific needs. As operations grow, the system can be expanded by adding compressors or modifying configurations, making it a future-proof investment.
Vari-Air systems can be installed indoors or outdoors, provided there is ample fresh air supply. To address this, Vari-Air offers complete enclosures called the Powerhouse—weatherproof, prewired structures designed to maximize fresh air intake. With controls mounted outside and the blower housed inside, this setup enhances durability while providing easy access for operation and maintenance.
Unmatched Customer Support
Beyond its innovative technology, Vari-Air is recognized for its exceptional customer service. Their team provides hands-on assistance during system startup and remains readily available for any questions. We have developed a strong working relationship with Josh and the Vari-Air team, who are not only colleagues but also trusted partners.
Additionally, Vari-Air actively listens to customer and vendor feedback, continuously improving its products for better usability and installation. They offer essential accessories such as cyclones, deadheads, and distributor valves, ensuring that newly installed systems are fully equipped for peak efficiency.
JPS Vari-Air has also prioritized dealer training for dealers like us and user-friendly operation. Their systems include stickers and QR codes at critical points, providing intuitive operational, maintenance, and checklist guidance for seamless usage.
The Clear Choice for Pneumatic Air Systems
When comparing Vari-Air to other air system brands, the difference is clear. Vari-Air leads the industry with continuous innovation and superior performance. If you’re considering an air system for your operation, give us a call today. We’ll help you determine the right size, capacity, and design to ensure a smooth and efficient installation process.
