Chinese New Year shutdowns give industrial facilities a much-needed pause, but restarting operations can expose hidden risks if critical systems are not handled correctly. One of the most overlooked areas during post-holiday restarts is the air compressor system. Although it may appear robust and ready, prolonged inactivity can introduce mechanical, electrical, and operational issues that only surface once production resumes.
Compressed air supports everything from manufacturing lines to instrumentation and pneumatic tools. A single mistake during restart can ripple across operations, causing downtime, inefficiency, or even permanent equipment damage.
To ensure a smooth return to work, here are five common air compressor mistakes to avoid after CNY shutdowns and what should be done instead.
1. Skipping A Structured Pre-Start Inspection
The first and most costly mistake is assuming that a compressor can simply be switched back on after weeks of inactivity. During shutdowns, environmental factors such as humidity, dust, temperature changes, and vibration settling can quietly affect system components.
A proper pre-start inspection should always be conducted before energising the system. This includes checking belts for slack or cracks, inspecting hoses and fittings for leaks, ensuring electrical connections are secure, and confirming safety guards are intact. Internal components may also require manual rotation checks to confirm that nothing has seized or become obstructed during the idle period.
Failing to conduct this inspection often results in start-up failures, abnormal vibration, or sudden mechanical breakdowns within the first few hours of operation. These failures are rarely caused by major faults, but rather by small issues that went unnoticed due to rushed restarts.
2. Restarting The System Too Aggressively
Once inspections are complete, the next common mistake is restarting the system too quickly and under full load. After a long shutdown, compressors require a controlled and gradual return to normal operating conditions.
Lubrication needs time to circulate properly, pressure must stabilise, and thermal conditions need to normalise. Starting the compressor at full capacity immediately can place excessive stress on bearings, seals, and rotating components that have been idle for an extended period.
A disciplined restart process allows operators to observe system behaviour during low-load operation. Unusual sounds, pressure fluctuations, or temperature spikes can be identified early, before they develop into serious failures. Rushing this step often shortens equipment lifespan and increases long-term maintenance costs.
3. Neglecting Condensate And Moisture Management
Moisture is one of the biggest enemies of compressed air systems, especially in humid environments. During shutdowns, condensate in your air compressor continues to accumulate inside air receivers, piping, and moisture traps. If left unaddressed, this moisture leads to internal corrosion, bacterial growth, and contamination of downstream equipment.
A common post-CNY mistake is failing to drain tanks and lines thoroughly before restart. Automatic drain valves may also malfunction after prolonged inactivity and should never be assumed to be working correctly.
Water carryover can damage pneumatic tools, affect product quality, and compromise sensitive processes. Proper condensate removal before start-up protects not just the compressor, but every system that relies on clean, dry compressed air.
4. Assuming Maintenance Is Not Needed After Idle Time
Another misconception is that equipment does not require maintenance simply because it has not been running. In reality, idle periods can worsen existing wear conditions and allow consumables to degrade unnoticed.
Oil levels may drop due to settling or leakage, filters may become clogged with accumulated dust, and seals may harden over time. Restarting without checking these elements often results in reduced efficiency, higher energy consumption, and unexpected shutdowns soon after operations resume.
Routine maintenance checks after CNY should include oil inspection, filter assessment, leak detection, and verification of lubrication points. These simple actions significantly reduce the risk of early-year breakdowns and improve system reliability throughout the year.
5. Overlooking Control Settings And Safety Devices
Modern air compressor systems rely heavily on automation, sensors, and control logic to operate safely and efficiently. After shutdowns, control parameters may reset, alarms may be disabled, or sequencing logic may no longer reflect current operational needs.
Failing to review these settings can lead to compressors short-cycling, operating outside optimal pressure ranges, or failing to shut down during abnormal conditions. Safety relief valves, temperature sensors, and pressure switches should always be verified before returning to full production.
Ignoring control and safety systems does not just risk equipment damage. It also puts operators and facilities at unnecessary risk. A short verification process ensures the compressor responds correctly under both normal and fault conditions.
Why These Mistakes Happen So Often After CNY
Post-holiday restarts are often rushed due to production deadlines, manpower constraints, and pressure to meet output targets. Maintenance teams may be understaffed during the first week back, while operations teams push to resume normal output immediately.
These conditions make it easy to overlook best practices, even in well-managed facilities. However, most compressor-related failures after CNY are preventable and trace back to restart discipline rather than equipment age or quality.
Facilities that treat restarts as a critical operational phase, rather than a simple switch-on task, experience fewer failures, smoother production ramp-ups, and lower long-term maintenance costs.
Building A Better Post-Shutdown Restart Culture
Avoiding these five mistakes requires more than technical knowledge. It requires a structured restart checklist, clear accountability, and alignment between maintenance and operations teams.
Documented restart procedures, scheduled inspections, and monitored ramp-up periods help standardise practices across shifts and personnel. Over time, this approach builds a culture where equipment reliability is prioritised, rather than reactive repairs.
Compressed air systems are long-term investments. Treating post-CNY restarts with care preserves that investment and protects operational continuity.
Conclusion
Restarting an air compressor after a Chinese New Year shutdown is a critical moment that sets the tone for operational performance in the months ahead. Skipping inspections, rushing restarts, ignoring moisture, overlooking maintenance, and neglecting control systems are common mistakes but entirely avoidable ones.
With proper planning, disciplined procedures, and experienced technical support, facilities can return to full operation safely and efficiently. Winston Engineering works closely with industrial clients to support reliable compressed air systems through every phase of operation, from maintenance planning to performance optimisation. A careful restart today ensures fewer disruptions, lower costs, and stronger system reliability for the year ahead.
