Screw compressor overhaul
Modern Tech Group performs comprehensive general and major overhauls of screw compressors in industrial plants. Our work includes airend regeneration, bearing and seal replacement, oil system regeneration, and control system calibration and repair.
Every overhaul is carried out by qualified service technicians with many years of experience and is covered by a warranty on the work performed. We guarantee fast turnaround and minimal production downtime.
Overhaul scope
Every overhaul is delivered end-to-end - from disassembly and diagnostics, through regeneration, to commissioning and performance testing.
Airend regeneration
We restore precise rotor clearances and geometry - the airend recovers full capacity.
Bearing and seal replacement
We use only proven, certified components for durability and reliability.
Oil system regeneration
Cleaning, cooler replacement - we eliminate overheating and leaks.
Control calibration and repair
Diagnostics of controllers, sensors and transducers - full control of machine operation is restored.
When does a compressor need overhaul?
If you notice any of the symptoms below, your compressor may need a general overhaul.
- Noticeable drop in compressor capacity
- Excessive oil consumption
- Noise from the screw block
- High operating temperatures
- Alarm messages on the control panel
Contact our service team
We guarantee a fast turnaround. Get a free, no-obligation quote for the overhaul of your compressor.
Benefits of overhaul at Modern Tech Group
- Restoration of factory parameters
- Extended machine lifetime
- Energy savings of 20-30%
- Reduced failures and downtime
Case study: Paper mill, Greater Poland region
about 60%cheaper than buying a new unit
Full compressor output restored.
- Problem
- Air end failure in a Renner compressor - the risk of weeks of production downtime and the high cost of replacing the whole unit.
- Solution
- Air end rebuild instead of machine replacement: removal, regeneration of the element, new bearings and seals, clearance check, load test.
Lead time: 5 working days
Supported compressor brands
- Atlas Copco
- Kaeser
- CompAir
- Boge
- Worthington
- Ingersoll Rand
- Gardner Denver
- Airpol
- Alup
- Fini
- Abac
- Ceccato
- Mark
- Renner
- Almig
- Gudepol
- Power System
- Fiac
- Hitachi
- Sullair
- Quincy
- Balma
- Ekomak
- Dalgakiran
- Shamal
- Dari
- Chicago Pneumatic
- Aerzen
- Pneumofore
- Elgi
- Kaishan
- SCR
What a full overhaul of a rotary screw compressor covers
A full overhaul is the planned rebuild of a rotary screw compressor that has run tens of thousands of operating hours and no longer holds its original specific power. We strip the package down: drive motor and coupling, air end, oil separator vessel, thermostatic valve and oil circuit, oil and air coolers, minimum pressure valve, inlet regulator, drive belts or gear train, and the control cabinet with its transducers. Each assembly is measured against the manufacturer's service limits before we decide whether it is reused, reconditioned or replaced, so the quotation describes real wear instead of a blanket parts list.
The mechanical core of the job is the air end. We check radial and axial rotor clearances, rotor tip and end-face condition, housing bore wear and the state of the discharge port. Bearings are replaced as a complete set with the shaft seals, O-rings and the balance piston seal, because mixing a new bearing pack with aged sealing elements is the most common reason an overhauled machine leaks oil again within a season. Rotor profiles are cleaned of varnish and carbon deposits, the compression chamber is degreased, and the assembly is torqued and shimmed to the clearance window specified for that air end family.
In parallel we rebuild everything that decides discharge temperature and oil carry-over: coolers are chemically cleaned or renewed, the separator element and its return line orifice are replaced, the thermostatic element is verified against its opening temperature, and the oil charge is matched to the duty and ambient conditions of the plant. On the electrical side we test motor insulation resistance and winding balance, re-terminate power connections, verify contactor and star-delta or soft-start timing, and re-flash or re-parameterise the controller so pressure band, unloading logic and service counters match the way the compressed air system is actually operated.
Air end rebuild as an alternative to a complete overhaul
Not every worn machine needs a full rebuild. When the motor, coolers and control system are healthy and the symptoms point at the compression element itself - rising current draw at unchanged delivery, a metallic or rumbling noise from the block, growing oil consumption, vibration signatures at bearing frequencies - an air end rebuild restores the machine at a fraction of the downtime of a complete overhaul. The scope is narrower and precisely defined: clearance measurement, full bearing set, shaft seals, inspection and dressing of the rotor profiles, housing assessment, reassembly to specified clearances, then a run-in cycle.
We decide between the two paths after diagnostics rather than before. A typical assessment includes vibration measurement on both bearing planes, discharge temperature trend, oil sample evaluation for wear metals and oxidation, current draw against nameplate at a known network pressure, delivery estimate from pump-up time into a known receiver volume, and a controller fault history read-out. If wear is spread across several subsystems at once - element, coolers, motor and instrumentation all at the end of their service life, with repairs recurring every few months - a full overhaul is the sound commercial choice. If the wear is concentrated in the element, we rebuild the element.
Acceptance testing and keeping production running
Every overhauled machine goes through a documented run-up before hand-over. We record no-load and full-load current, discharge pressure and temperature, oil level stability, separator differential, pressure dew point downstream of the dryer where one is installed, and delivered flow estimated from receiver pump-up. Leak checks are performed warm, at working pressure, and the controller service intervals are reset. The customer receives a written acceptance record with measured values, parts installed and the recommended maintenance interval, so the next service provider - in-house or external - starts from a known baseline.
The job covers diagnostics, removal and refitting of the air end, the rebuild itself (bearings, seals, rotor regeneration and clearance setting) and re-commissioning. Where an overhaul would otherwise stop production, we place a stand-by screw compressor matched to your machine with the connection kit for the duration of the job.
Overhauls for international companies with plants in Poland
Part of our overhaul work is done for foreign-owned and international manufacturing groups operating production plants in Poland. Technical discussion, scope agreement and coordination are handled in English, so the plant engineer in Poland and the group maintenance function abroad work from the same information.
- Overhauls and air end rebuilds for your plant in Poland
- English-speaking service engineers - direct technical contact
- Reports and hand-over documentation in English on request
- Stand-by compressor for the duration of the downtime
- Clearly defined scope per machine, agreed in writing before parts are ordered
Send us the machine data - brand, model, motor rating, operating hours and symptoms - and we will come back with a scope proposal for your plant in Poland.
Overhaul questions we are asked most often
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ul. Słowackiego 201 26-600 Radom Mazovian Voivodeship, Poland