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Air Hoist vs. Electric Hoist

Author Headshot - Charles
Charles
Aug 16, 2023

This article compares electric and pneumatic hoists, examining the differences in usability, environment, and cost. It focuses on seven categories, including duty cycle, speed control, weatherproofing, installation and operation, maintenance costs, investment costs, and safety, to help determine which type of hoist is best suited for your operational requirements.

Hoists are used to safely and efficiently move loads in various industries. While electric hoists are more common, a pneumatic hoist may be better suited for your needs.

This article will help you determine which type is best for you, considering seven factors: duty cycle, speed control, weatherproofing, installation and operation, maintenance costs, investment costs, and safety.

How to Choose the Right Hoist

Hoists are commonplace in most production industries because they provide safe and efficient hoisting and maneuvering of loads. The functioning principle is simple: A wire rope or chain is wrapped around a wheel that is connected to a gear system. Hoists can be operated manually or powered with electricity or air. The load is lowered or raised by increasing or decreasing the length of the rope or chain. 

One of the biggest factors in usability for different environments and cost is how the hoist is powered. Putting manual hoists aside for a minute, this article is going to focus on the differences between electric and air (or pneumatic) hoists. While electric hoists are the most commonly used, pneumatic power may be better suited to your operational requirements. 

To help determine whether your hoisting needs are best served with an electric or pneumatic-powered hoist, we are going to look at seven categories:

  • Duty cycle
  • Speed control
  • Weatherproofing
  • Installation and Operation
  • Maintenance Costs
  • Investment Costs
  • Safety

Benefits of a Pneumatic Hoist

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Pneumatic hoists—sometimes referred to as air hoists—can offer specific benefits to production facilities, especially where power supplies are not available or where environmental conditions are not suitable for electric power. However, there are many more advantages that are often overlooked:

Duty Cycle

Because pneumatic hoists are powered by compressed air, there is virtually no risk of overheating meaning that they can have a 100% duty cycle. In other words, they never require downtime and can be used uninterrupted. The gearbox may generate some heat from prolonged use so it is best to choose an air hoist that incorporates a system for self-cooling. 

Speed Control

Variable speed control is achieved by regulating the pneumatic pressure of the hoist. It can be done with great accuracy using control valves—compared with traditional gearing—meaning that a wide range of speeds is possible. This range is ideally suited to positioning loads with greater accuracy and care. 

Thanks to the reduced amount  of moving parts and no limitations of input power, variable speed control is generally available at a lower price compared to an electric hoist.

Weatherproofing

As there is no risk of electric shock, pneumatic hoists are not subject to the same IP rating system as electric hoists. If contaminants do get inside the hoist, they are usually blown out by the pneumatic airflow and should not cause any worry of impeding the duty cycle. This reliability is especially important in environments where the hoist will need to be cleaned regularly such as in the aerospace or chemical industries. It also means an air hoist is better suited to humid environments.

Installation and Operation

Pneumatic hoists are generally lighter in weight than electric hoists and are easier to install because the technology involved is far simpler. This means that in most cases they do not need to be installed by qualified personnel. Their lighter weight also means that air hoists are easier to handle and move making them well-suited to mobile applications. 

Investment and Maintenance Costs

There are relatively few mechanical components in a pneumatic hoist compared to an electric hoist. This simply means that there is far less that can go wrong with it but replacement parts tend to be more expensive than electric parts. 

While pneumatic hoists may be more expensive than electric hoists, they enjoy reduced maintenance costs over their lifetime because there are fewer parts to go wrong and they are not subject to routine checks and maintenance like an electric hoist. That and the lack of downtime will provide cost savings for production in the long term.

Safety

Air hoists are often used in potentially explosive environments such as oil rigs, chemical processing plants, mines, and paint shops. Because they are operated by air there is no risk of a spark making them suitable for the most extreme conditions with excessive dust or even where flammable chemicals are used. 

What are the Downsides to a Pneumatic Hoist?

While there are many advantages to a pneumatic hoist, there are equally some downsides. However, some of these do come with caveats as mentioned above.

  • Pneumatic hoists require a compressor to function. This is an additional cost and it is likely to require maintenance over time increasing spend further. The compressor requires power to operate meaning that there is still a chance of downtime caused by electrical issues, albeit site power supply issues which are less common.
  • As well as the unit cost of a pneumatic hoist being higher on average than a comparable electric hoist, the need for a compressor adds to this making the overall investment significantly higher.
  • Pneumatic hoists are also a lot louder when in operation compared with an electric hoist. This may require that operators use additional PPE equipment to cover their ears if operating the air hoist for a long period. Attempts have been made to reduce their noise output but it often results in power deficiencies.
  • Because they are air-powered, pneumatic hoists have a lower load rating than electric hoists, around a ton. They are unable to achieve the required torque to lift and sustain the weight of a heavy load.
  • The air supply also means that pneumatic hoists do not respond as quickly to controls compared with electric hoists. This is because the length of the control lines is directly related to delay times in movement. The longer the line, the longer the delay. 

Benefits of an Electric Hoist

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Electric hoists are used so much across all industries for good reason. They represent great value, are available in various options, and are easy to operate among many other reasons:

Duty Cycle

Electric hoists are limited in the length of their duty cycles mainly because they can overheat. That said, they lift heavier loads because the electrical input can generate higher torque. This can increase productivity and make the hoist suitable for a broader range of lifting tasks, negating their drawbacks in the duty cycle. Electric hoists can also be equipped with hazardous-duty motors for use in dangerous and explosive environments. 

Speed Control

Depending on usage requirements, electric hoists are available in many different speed options. The most common are single, two-speed, and variable-speed options. Because of their electrical configuration, there is less available range for hoist speeds compared to pneumatic hoists. However, the speed is more direct, and small adjustments can be made more accurately; there is no delay in response from the controls to the motor.

Weatherproofing

With voltage as its power source, it is not surprising that electric hoists are not suitable for humid environments. This is because as well as humidity collecting on the surface of an electric hoist, it can also collect on the chain or wire rope and be drawn up toward the motor increasing the risk of humidity coming into contact with the electric system. 

Installation and Operation

There is not much that can compare with the lifting capacity of an electric hoist. Some models can handle loads of up to five tons while still being portable. This is one of the biggest advantages over pneumatic hoists which are usually limited to a ton in capacity. 

Electric hoists also provide very smooth and precise motion for maneuvering loads more efficiently and safely. But as with any hoist, training for safe and efficient operation is necessary.

They require relatively simple mounting if there is a suitable structure for rigging within a worksite. The installation of proper electrical wiring and connections will involve specialist personnel to ensure the power supply is suitable and correct. More complicated electrical installation will also increase costs.

Investment and Maintenance Costs

Electric hoists are generally cheaper than comparable pneumatic hoists, mainly because they are more widely used in production and various industries where the quantities of production bring the costs down. Another consequence of this is that replacement parts tend to be cheaper and there is more availability of maintenance and technical support which contributes to reducing long-term costs. 

It is worth noting that in addition to maintenance costs from general use, production sites will be subject to regular inspection for electrical equipment to ensure safe and efficient operation. These inspections may be carried out by in-house maintenance personnel or by qualified technicians. The options available to you will further influence long-term costs.

 The frequency of these inspections may vary but it is advised for them to be annual or semi-annual. With regular inspections and maintenance, you can expect the life of an electric hoist to be roughly 10 years. 

Be aware that maintaining proper documentation, such as maintenance logs, inspection records, and compliance with safety regulations,could incur some administrative costs. This may include record-keeping software, safety certifications, or regulatory fees.

Safety

When it comes to safety, electric hoists offer several notable advantages, making them a reliable choice in many work environments.

With variable speed controls, electric hoists provide precise control over lifting and lowering loads. This minimizes the risk of collisions, swinging, or sudden movements that could risk personnel safety or equipment damage. 

They also tend to include safety features such as limit switches to prevent overtravel of the chain, emergency stop buttons, and load brakes to prevent loads from suddenly falling in the event of gear failure or overloading. Many models also include overload protection so that the hoist will not function if load capacity is exceeded. 

What are the Downsides to an Electric Hoist?

Even though electric hoists are very widely used across various industries, they are not suitable for all situations:

  • While insulation and motor technology have come on hugely in recent years, there is still the risk of electrical sparks being generated. For this reason, electric hoists are usually not suitable for environments that require explosion-proof machinery. There are special electric hoist models that are designed to operate in extreme conditions with dust and gas-proofing and explosion-proof motors.
  • Because electric hoists operate using electricity, a site power shutdown can disrupt production resulting in costly downtime. Back-up generators are not suitable for variable speed  electric hoists because the hoist’s computer requires clean electrical supplies.

Is a Pneumatic Hoist or Electric Hoist Right For You?

The greatest advantage of a pneumatic hoist is that it can be used safely within a higher-risk environment such as mining, chemical processing, and even paint shops. Regardless of how good an electric hoist is, it has an inherent risk of causing a spark through malfunction or improper operation. 

Electric hoists are more diverse in the available options, particularly capacities, making them a more cost-effective alternative to air hoists. They can also hoist significantly larger loads (up to 5 tons) meaning they can serve some production facilities better than the ½ ton capacity of an air hoist. 

Electric hoists include many safety features, but it is important to consider the specific application requirements and potential hazards present in the work environment. 

Where To Find The Best Pneumatic and Electric Hoists

If you are still unsure whether a pneumatic or electric hoist is better suited for your specific requirements, you can contact our expert team who will be happy to help. 

When choosing a pneumatic hoist or electric hoist, you should remember that reliability is arguably the most important feature. You can do this by purchasing from a reputable company that stocks trusted brands that comply with the associated standards required for your industry. 

But fear not, buying from trustworthy sources does not mean you have to pay more. You can get significant industry discounts on electric chain hoists through a supplier like PWI for bulk orders or by going direct to HoistZone.com for the best deals online. 

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