Best 60-Gallon Air Compressors | 2022 Impressive Buyer’s Guide

What is the best 60-gallon air compressor? First of all, your choice depends on what kind of tool you are going to use. If you deal with heavy-duty tools, choose a model that provides more pressure and has a larger volume. Another thing to consider is horsepower. Typically, air compressor horsepower ranges between 1.5 and 6.5 HP — the more powerful your tools are, the more horsepower you need. Air pressure rated in PSI is another important value. Generally, air tools need 90 PSI to operate properly. Also, look at CFM (cubic feet per minute), which is the volume of air produced by a compressor. You should also consider the air compressor user-friendliness, the level of noise it produces and portability. These devices are typically bulky, so a more lightweight and compact model will have a clear advantage over others. We believe that Industrial Air ILA4546065 60-Gallon Air Compressor meets these criteria best.

A large 60-gallon air compressor is made to run power tools that require significantly more air pressure. These air compressors are stationary, not portable, and run longer. They are typically used for industrial jobs, although there are models that are well-suited for the DIY garage.

When Will You Need Such A Large Volume Air Compressor?

Some large air compressors are specifically designed for industrial use while others accommodate DIY and home use. The tools you intend to use with the air compressor determine the size of unit you need. For example, a high volume air compressor is needed when an air tool like a grinder, sander or sandblaster will be run continuously for long periods.

If you intend to use multiple air tools, choose an air compressor that is powerful enough to support the largest ones. If you have a shop or business you may want a large volume compressor that can run multiple tools simultaneously.

How Do These Larger Air Compressors Work?

Simply put, pressure inside the air compressor’s chamber increases when the piston compresses the air, decreasing its volume. The air compressor should have a reliable high-flow regulator and reach the set pressure (PSI) reasonably fast. It must hold its supply without losing pressure. The air compressor’s tank stores air under pressure until it is needed to power a pneumatic tool that is connected to the air compressor by a supply line.

Reciprocating piston compressors have a crankshaft, connecting rod to a piston, cylinder and valve head. Larger air compressors are typically a rotary screw (positive displacement) type specifically designed for complex applications (see below). The larger the tank, the greater the volume of air it can hold. For maximum efficiency, a large (60+ gallon) air compressor should also maintain a 100% duty cycle.

What Types of 60-gallon Air Compressors Are There?

Reciprocating Piston Air Compressors

This type of air compressor has a (back and forth) pulsating piston and crankshaft similar to that of an internal combustion engine. The rapidly moving piston draws in air. Pressure increases as the crankshaft pushes the piston closed and air volume in the chamber is compressed Air is drawn in as the piston opens. This air compressor may be gas-powered or electric, but not always sufficient for heavier industrial uses. 

Rotary Screw Air Compressors

Oil-sealed rotary screw air compressors are designed for maximum air intake to run complex and high-powered professional tools and heavy-duty applications for long periods. This type of air compressor employs a positive displacement compression system similar to a hot rod’s turbocharger. Air pressure is generated by two freely rotating helical screws. The benefits of having fewer moving parts are reduced operation noise and low maintenance. 

Oil and Oil-Free Compressor Systems

Larger air compressors are typically oil-injected or oil-free units. Commonly used oil-injected screw air compressors are less expensive than oil-free units. They are better quality, quiet and more expensive to purchase and maintain than oil lubricated piston air compressors. 

Electric and Gas Air Compressors

Electric units are less expensive to run and can run for long periods without needing to refill the fuel tank. They are quieter and may be used wherever there is a power source. Large volume electric air compressors are more eco-friendly and require little maintenance. Mobility depends on source availability.

Large gas-powered air compressors are more powerful than comparably-sized electric ones. They may be too heavy, due to their size and weight of the fuel, to be mobile. Gas-powered air compressors are best-used outdoors. They require more maintenance, oil and fuel refills. 

How Are 60-gallon Air Compressors Different From Less Powerful Ones?

The larger tank size determines how long the attached tool can run before the compressor’s motor has to create more compressed air. Larger air compressors also have fewer moving parts which increase their reliability and reduce noise and maintenance. Dual and three-stage models are specifically designed for high efficiency. Stationary and industrial-grade air compressors must be installed by a certified installer.

What Is The Difference Between Single-Cylinder, 2-Cylinder, And 3-Cylinder Models?

Air compressor models are categorized according to operational stage and cylinder compression power.

Single-stage models use a piston to compress air in one stroke. A full rotation of the crankshaft drives the piston a full motion. They typically deliver a maximum of 155 PSI. Electric units run on 120V household or 12-volt accessory current. Some single-cylinder models, multiple pistons are used to divide up the work and can operate at lower rpm and decibel.

Two-stage models typically deliver 175+ PSI at 100+ PSI CFM. Air is compressed in the first stage by one piston and moved into a smaller cylinder where it is compressed again by a second piston. This system doubles the air pressure that is stored in the tank.

Multi-stage models are predominantly used in industry. They have 60+ gallon tanks for maximum efficiency and typically deliver 175+ PSI. They operate at slower, cooler CFM. 

What is the refill rate?

System demand determines the air compressor’s tank size. This includes the unit’s compressor size and system control, fluctuating air volume and pressure, expected temperatures, and how and where it will be used. The refill rate is how long it takes the tank to refill with pressurized air.

How powerful the air compressor’s motor is determines how fast the air enters the cylinder and how fast the tank can refill. Motor horsepower (hp) is affected by the total compressor air volume delivered at a specific pressure. Excess air volume, or artificial demand, may be reduced by adding an air receiver. The air receiver optimizes efficiency by reducing compressor loading and unloading cycles.

New technologies such as variable speed drives (VSD) have made air compressors more powerful, cost-effective and energy-efficient. VSD allow the compressor to alter motor speeds and voltage as air demands change. Variable frequency drive (VFD) technology alternates between A/C and D/C power and controls frequency and voltage input to further allow the air compressor to control the motor speed and torque.

What Are The Main Characteristics Of Air Compressors?

Power (CFM) and Pressure (PSI)

The more air that is stored, the easier it is for a compressor pump to deliver and maintain CFM's at the desired PSI.

Airflow volume is measured in cubic feet per minute (CFM). It indicates the rate at which air moves into a compression cylinder and the unit can compress it. The higher the CFM’s, the more volume of air a compressor can generate and the more power the unit generates to run the attached pneumatic tool. Larger air compressor tanks store greater volumes of air. Stationary models typically produce more power than portable ones.

The amount of air pressure the compressor unit can release is measured in pounds per square inch (PSI). The higher the PSI, the more air pressure the unit can capably release. The air pressure is set using the air line regulator according to the tool used.

Duty Cycle

The duty cycle is how long the air compressor can run before it automatically shuts off to cool down. It is the percentage of time (in 10 min. increments) the pump is allowed to run. Large volume air compressors that are intended to run for long periods need a continuous air flow to accommodate the constant run time, which is equal to a 100% duty cycle.

Noise Level (dB)

Air compressors average between 40-90dB. Single-piston, gas-powered units are the noisiest. Low-noise models have few moving parts and are oil-free. Electric and screw air compressors are quiet by design.

How Do You Correctly Move, Install And Repair Such Large Air Compressors?

New large air compressors may be moved upright or on their side. Used air compressors should always be moved in their upright position. Large gas-powered units are heavier and not easily transportable unless they are truck-mounted or are wheelbarrow style.

Stationary and industrial-grade air compressors and manufacturing solutions must be installed by a certified installer familiar with applicable state and local codes, power and application requirements.

To ensure longer life, drain the moisture from your air compressor’s tank after every use.

TOP-3 Best Heavy-Duty (60-80-Gallon) Air Compressors

Below, you will find a review of the three best heavy-duty air compressors at a price ranging from $1,000 to $5,000. The first one is a three-cylinder device with an oil-lubricated pump. The second one is an ultra-quiet model with an oil-free pump. And the third product is a super powerful rotary screw air compressor with an 80-gallon tank.

1. Industrial Air ILA4546065 60-Gallon Hi-Flo Air Compressor

The Industrial Air ILA4546065 is a single-stage, three-cylinder, large capacity ASME-certified 60-gallon air compressor. It is for professional trades as well as industrial operations. Its heavy-duty induction motor, rugged design, longer duty cycle run times and quick recoveries specifically benefit mechanic shop and farm and livestock operations.

With an independent power source it can be equally well-suited for service truck utility functions. The Industrial Air ILA4546065 reliably runs impact tools (hammers, wrenches, etc.), ratchets, spray guns, and more.

This is a stationary, electric, high-flow air compressor that operates on a fully-wired 240V, 20 amp 4.7 hp induction motor designed to protect against voltage fluctuations. The Industrial Air ILA4546065's pump is rated at 155 PSI maximum operating pressure and 16.1 SCFM at 40 PSI and 14 SCFM at 90 PSI. Its splash type oil lubricated pump has a thermally stable cast iron cylinder body and aluminum head and valve plate and features a one-piece cast iron crankcase. It has automotive style ball bearings and durable Swedish stainless steel flex reed valves and 12 in. cast iron balanced flywheel. It operates from a 6 ft., 12 gauge power cord.

The Industrial Air ILA4546065 air compressor also features an easy-access oil fill with an oil level window, a pressure gauge, and convenient On/Off switch. This product ships with a full metal belt guard and synthetic oil.

Industrial Air: Check the current price

2. California Air Tools CAT-60040CAD Ultra Quiet 60 Gal Compressor

The CAT-60040CAD is a single-stage, single phase, steel ASME-certified 60-gallon air compressor made by California Air Tools. It has two 2.0 hp SP Series motors (230V, 14 amp draw) that run at a low 1680 rpm, making it one of the quietest, long continuous running duty cycle 4.0 hp air compressors on the market. It operates at 70-75 db (“30% less noise”) making it appealing for shops and garages as well as the professional trades. It reliably runs staple and nail guns, airbrushes, blow guns, and more. It includes thermal overload protection.

This corded electric air compressor’s oil-free, dual piston pump system is rated at 125 PSI maximum operating pressure and 12.60 SCFM at 40 PSI and 10.60 SCFM at 90 PSI. It has a designed 3000+ hour life cycle, which surpasses other comparably sized and equipped 1500-hour life cycle air compressors. It reliably starts regardless of temperature or terrain.

The high performance, low maintenance CAT-60040CAD air compressor also features an automatic purging system and easy-to-read pressure gauge and regulator. Four engine filters are included.

California Air Tools: Check the current price

3. HPDAVV PACK7-TA Rotary Screw Air Compressor

The all-in-one, high performance, 80-gallon HPDAVV PACK7-TA electric air dryer and tank unit is a three-phase industrial rotary screw air compressor. It runs on a reliably powerful 230V / 60 Hz, 24 (full load) amp, 10 hp / 7.5 Kw air-cooled, belt-driven, fixed speed motor.

This model delivers a maximum air flow of 39 CFM at 115 PSI. It provides continuous duty cycle performance and a long life cycle. The device is intended for commercial use only. Its rotary screw elements are enclosed allowing the unit to operate at a quiet 80 db.

This industrial air compressor has a maximum operating pressure of 125-150 PSI. It also features high performance modulation control and a microcomputer control system. A high precision integrated spin-on air oil separator has been specifically designed to efficiently lower the oil contained in compressed air and send the filtered oil back to the air end.

The HPDAVV PACK7-TA requires minimal and easy maintenance. Annual maintenance only requires scheduled oil and spin-on separator filter changes. There is easy access to components which are inexpensive to replace.

HPDAVV: Check the current price

8 Best-Selling 60-Gallon Air Compressors Comparative Table