Whatever industrial sector you work in, rotary screw compressors are an important part of your daily routine. Compressed air has become the fourth utility and is just as vital to production, in most cases, as electricity, gas, and water. If you regularly use a rotary screw air compressor in GA, you know how important it is to properly maintain your compressor.

Read full post at: https://pyebarker.new.imsguys.com/maintaining-your-rotary-screw-compressor-in-ga

Whatever industrial sector you work in, rotary screw compressors are an important part of your daily routine. Compressed air has become the fourth utility and is just as vital to production, in most cases, as electricity, gas, and water. If you regularly use a rotary screw air compressor in GA, you know how important it is to properly maintain your compressor.

But it is easily neglected, until it stops working, that is. It is important for your compressors to be properly maintained for your equipment to remain reliable and efficient, in order to maintain profitable production.

Despite their rather complex design, a rotary screw compressor’s basic function is simple – when two screws turn, air enters into a chamber. As the screws turn, the area in the chamber gets smaller, causing a decrease in volume and a rise in pressure.

But while the basic function is simple, many complex parts work together for a rotary screw air compressor to operate correctly. Thus, like any other mechanical equipment, such as a car or a lawnmower, your rotary screw compressor in GA requires regular maintenance.

Due to the complex nature of the compressor, safety, oil types, and the importance of reliable and efficient operation, it is highly recommended that you consult a trained and competent person before doing any maintenance to this type of equipment.

Practice Safety First: As with any other equipment, proper protective gear and training prior to operating, adjusting, or maintaining a compressor is required. Be aware of safety risks – always lock and tag out the electrical supply as well as the isolation valve on the compressed air piping. Confirm that the power is off with a reliable meter, and vent all air pressure prior to performing maintenance.

Lubricants: Just like a car needs regular oil changes to maintain lubrication between its moving internal parts, your rotary screw compressor in GA requires periodic lubricant changes. Oil in a rotary screw compressor is used to cool, clean, and seal, which means the compressor oil is that much more important to the compressor’s operation. If you fail to change the lubricant, it will become contaminated with acid or even varnish and clog the oil filter.

Filters: Your rotary screw compressor has an oil filter, an air inlet filter, and an air/oil separator. Like changing the oil, changing the filters will prevent your compressor’s parts from failing prematurely and prevent the oil from becoming contaminated. You should replace both the air filters and oil filters every 2000 hours of use at a minimum. In dirty environments the filters may need to be changed more often.

Inspections: The screw element of your compressor is the heart of your compressor. While they can last well over 40,000 hours, they might still incur damage before they reach that point. Overheating, improper lubrication, condensation, corrosion, over pressure, incorrect control adjustment, and vibration can all lead to premature failure. Check for oil seal leaks and bearing noise.

Motor Bearings: The motor bearings require periodic lubrication to keep the bearings cool and prevent them from thermal breakdown and premature failure. Types of motor grease and the amount of grease used are crucial in an electric motor. Over greasing motor bearings will cause premature failure. Mixing grease types will also cause bearing failure.

Questions regarding how to maintain your rotary screw compressor in GA? Give us a call today and we’ll be happy to help.

Compressed air has become a vital utility in the day-to-day operations of most companies. Businesses are well aware of the need for compressors, but there is considerable debate as to which of the two most popular types – rotary screw or reciprocating – works best in an application. As a supplier of Gardner Denver compressors, today we’re discussing similarities and differences between them to help you select the best one for your application.

Power Transmission Air Compressors

Rotary screw compressors are used extensively in applications above 30 hp and for air up to 150 psig.  Reciprocating compressors cover low horsepower and demanding applications where reliability is essential.

Gardner Denver compressors are used with a wide range of gases, but air compression is the largest application. Stationary rotary screw compressors account for about 40% of the air market, while reciprocating Gardner Denver compressors possess 21% of market share by dollars.

Above 30 hp:  Rotary screw compressors have taken over nearly all of the standard plant air 100-150 psig market above 30 hp. Improvements in the performance and reliability of these compressors, coupled with reduced maintenance and lower initial cost, are key factors driving this trend.

Although a double-acting reciprocating is still the most efficient compressor, rotary screw models have narrowed the efficiency gap. Better rotor profiles, machining improvements, and design innovations are contributing factors.
Maintenance:  When it comes to maintenance costs, Gardner Denver rotary screw compressors have an advantage over reciprocating. Double-acting reciprocating compressors typically require more periodic maintenance than rotary screws. Valves, piston rings, and other consumables on a reciprocating compressor need expensive routine maintenance.

Rotary screw compressor maintenance is limited mostly to oil, oil filter, and air/oil separator changes. At some point there is a sizable cost associated with a rotary screw air end replacement, but they often last 10 years or more.

Lubrication:  Reciprocating Gardner Denver compressors are divided into two categories – lubricated and non-lubricated. In lubricated units, oil is introduced into the compression cylinder to minimize wear of the cylinder and piston rings. In an average application, lubricated rings should last for several years. Advances in new compression ring materials are extending ring life in non-lubricated units to more than 8000 hr.

Below 30 hp:  Small air-cooled reciprocating compressors have been used extensively in applications requiring pressures up to 175 psig. Large and small air-cooled units are well suited for use in harsh environments.

The most common small reciprocating compressor is the single-acting design. Operating temperatures can reach 380 F and most units operate at sound levels above 80 dBA.

For lower horsepower applications, reciprocating Gardner Denver compressors are considered a good value because the initial purchase price is generally 40-60% less than a rotary screw compressor.

Installation:  Small reciprocating machines should be used with an air receiver. The receiver stores compressed air and minimizes the loaded run time of the compressor. Some small reciprocating compressors have a limited duty cycle of around 66%.

It is particularly important to the life of these compressors to use an adequately sized receiver. No matter what the receiver size or configuration of the compressor and receiver, small reciprocating machines are relatively easy to install. Any reciprocating compressor should always be anchored to the floor due to unbalanced forces.

The majority of small rotary packages are designed to stand-alone. Base-mounted units can be mounted on top of an air receiver. Air is discharged from rotary screw compressors without pulsations. However, it is a good idea to include a receiver in the system to smooth the control air signal back to the compressor controller and provide consistent operation.

Overall, compressed air quality from rotary screw compressors is good. Even though the rotary can be an oil-flooded machine, an efficient air/oil separator reduces oil carryover into the compressed air system to less than 5 ppm.

Need help choosing the right Gardner Denver compressor for your application?  Call us today and one of our experts will answer all your questions and assist you in making the right decision.

I know that we’ve been hearing a lot about oil free air compressors of late. Some of you might be wondering about the hype. I believe they are worth the hype and they can represent incredible value to the right customer.

I suspect that as we move forward and the technology becomes more widespread, the costs will come down and we will see the broader market turn to oil free air.

So I’m going to share the ideal situation to consider an oil free air compressor.

Where I Would Look Long And Hard At Oil Free Air Compressors.

Gardner Denver Oil Free Air Compressors do deliver 100% oil free air. No conventional air compressor can offer that. Once oil is in your compressed air it’s impossible to get it 100% out. No scientist would make that claim and no company would guarantee that their filtration system can clean air from conventional air compressor so that you get 100% oil free air all the time.

It’s just a recipe for legal troubles.

You can make those claims with an oil free air compressor.

ISO-Class 0 air is air that is 100% completely oil free. The best you can get with a conventional compressor is .1 mg/m3 under ideal conditions. I’ll admit it can be good enough but it requires a filtration system.

You don’t need to invest in or maintain an oil removal/filtration system if you use an oil free compressor. There’s a savings and depending on the quality of air you need it can be a big one over the life of a compressor.

Then there is always the risk of a contamination ‘event’ and downstream damage. This can be either from oil in the compressed air contaminating your end product – e.g. pharmaceuticals or food and beverage applications or the oil could damage your equipment that runs on compressed air e.g. pumps and tools.

Where you are looking to replace your air compressors anyway and would like to eliminate the costs or the ‘risk of expense’ associated with maintenance and repairs or product damage, that’s where there could be a big payoff. Cleaning up a disaster could well cost you far more than the oil free compressor would have cost.

If you are looking for a new compressor, the team here at Pye-Barker can guide you through the process. Please call 404-363-6000 or drop us a line sales@pyebarker.com and we will explore a range of options based on your circumstances with you.

It’s interesting to me that a lot of compressed air systems are allowed to grow organically.

Pumping systems are precisely engineered. Requirements are specified exactly. The system is evaluated on paper, future-proofed. Those designs are evaluated and double checked… Compressed air systems are not specified per se.

Compressed air system components are specified.

A lot of compressed air systems aren’t anywhere near as well engineered. Frankly far too many systems are a built out of a mish-mash of components, often with customization and often there are oversights in integration.

Eli Goldratt wrote a lot of books about using Theory of Constraints in business settings. Initially he was famous for optimizing the production of manufacturing systems. The big mistake he saw in a business was ‘optimizing each step of the process.’ He called it striving for ‘local optima.’

Independently specifying the best compressor, best drying system, best storage tank won’t produce the most overall efficient system.

Ultimately there will be one component that is the constraint on the system and it will determine the overall performance of the system. Kind of like a chain only being as strong as it’s weakest link.

The capacity of your compressed air system will be limited by the ‘weakest link.’

If I was to design a compressed air system from the ground up I would be looking at

Then I’d specify a system based around those criteria.

We know that most systems are already up and running and now many plant managers are having to add capacity or improve air quality or sometimes doing both to their existing compressed air systems. However, when there is no overall system consideration you can end up creating something like Frankenstein’s monster.

For example: if you add a new compressor with a Variable Speed Drive to an existing compressed air system. Say that new compressor runs at 50% speed and power. Say the system’s existing modulating compressor has cut its output and is now running at 20% capacity. That modulating compressor could still be using 75% of its full power load.

The new VSD operated compressor might be able to handle the base load at about 70% capacity and consuming 70% power. Instead, in this example, two compressors are running at 125% of the necessary power.

That’s obviously not optimal.

For a start you’d want is to update the controls for the system so that the VSD compressor handles the base load and the modulating compressor comes on to handle demand over a threshold and it is shut down when demand is below that threshold.

That’s really only the beginning of system optimization.

If your compressed air expenses are climbing (or if you can’t measure them accurately) or you think you need to expand your system, the first thing to do is to take stock of the system as a whole. If you don’t have the necessary expertise in-house, we will audit your compressed air system for you and guide you to getting the performance you need. To get started with a no-obligation discussion call 404-363-6000 or drop us a line sales@pyebarker.com

Up until very recently there have been two very good reasons why compressed air systems weren’t monitored beyond temperature and pressure.

  1. It was expensive to buy instruments capable of accurate measurements
  2. Cheap instruments were inaccurate

Thankfully, technology has come to the rescue and there are now lots of inexpensive instruments that are very accurate. Which means there is no excuse not to measure how your compressed air system performs – it pays to be tracking flow, power energy, dew point and key temperatures over time but this is very rarely done.

Stop and think about it for a second – here is a vital system to your operation. When your compressed air system goes down for planned or unplanned maintenance, the whole plant grinds to a halt or at best you’ve got a fraction of the productivity when it’s running.

On top of this – you are talking about one of your largest single energy cost centers in your plant. Surely you’d like to know if it is running efficiently or you are literally flushing perfectly good money down the toilet, as it runs inefficiently hour after hour, day after day.

All that needs to be done is logging of your data. Which is quite straight forward nowadays too.

“If You Can’t Measure It, You Can’t Improve It.”

Lord Kelvin.

The main purpose of measuring and recording data is so that you can improve performance. If we have a baseline we can see if the system is at least holding steady or if it is becoming less efficient i.e. its specific power is rising.

Having access to logged data over time will give you access to performance trends and valuable feedback when you make changes – did it make your system for efficient?

Identify Maintenance Issues

Just because the compressor controls say ‘everything functioning properly’ doesn’t mean they should be taken as gospel. Having a measuring system in place it means you can verify that what your compressor controls say is true.

Ensuring Pressure Stability

One of the common goals of a compressed air system is to provide a steady supply of compressed air at the right pressure – again, this is hard to monitor without data logging. Compressed air systems can take some wild swings in pressure. Some are just part and parcel of life and some have underlying causes. With data it can be possible to identify reoccurring pressure problems and pinpoint the causes.

Troubleshoot Problems.

When you have a problem, the best thing you can do is go back and review the actual data of what happened rather than rely on the memories of those involved. It’s easier to correct what actually went wrong rather than what you think may have gone wrong.

Verify Your Savings

If senior management is going to spend money improving your equipment they generally want proof that your project is going to pay off. Data logging systems give you that proof. Unfortunately it can mean that if your project fails you’ve got proof of that too. But we know you’re smarter than to recommend a project that won’t improve the operation.

Sizing Equipment

Data on the performance of your compressed air system is a big benefit when working with vendors. Firstly, it means they can’t sell you an over-specked system by exploiting your ignorance. Secondly it means you can have a more informed discussion based on hard data about what you can do to actually reach your goals for your system – be it around energy efficiency, flow rates, or air quality.

It also means you’ll know very fast if your investment was the right one or it wasn’t.

If you’d like to start monitoring the performance of your compressed air system the best thing to do is start with a compressed air audit. As part of the audit Pye-Barker’s team of engineers can design up a robust and inexpensive data monitoring system to suit your compressed air system. To get the process started call 404-363-6000 or drop us a line sales@pyebarker.com

When you’ve grown up around air compressors – literally in my case, it means that the jargon is second nature. However I know I often forget this when speaking to clients and often there is confusion when a couple of different terms get blurred.

So I thought I’d take the time to remind you of those easy to confuse definitions.

Compressor Capacity Definitions

Capacity is the quantity of air the compressor can pump out. Capacity is rated at based on the conditions of pressure, temperature and moisture content existing at the compressor inlet flange.

Mass flow (lb/min or kg/hr) Compressor performance is specified by a curve of delivery pressure against a mass flow rate for a constant velocity:

CFM (Cubic Feet per Minute) (M3/min) is a volumetric measurement not dependent on inlet conditions such as temperature, pressure and humidity.

ACFM (Actual Cubic Feet per Minute) (M3/min) represents ‘useful air’ and is independent of the seal losses through the machine. The commonly used value for seal losses with carbon seals is about 1%. Some centrifugal compressors may have other air losses between the inlet and discharge flanges.

ICFM (Inlet Cubic Feet per Minute) (or M3/hr) is a measure of the air entering the compressor. ICFM is the most common method of determining centrifugal compressor selection.

FAD (Free Air Delivered) indicates delivered air at inlet conditions. FAD is read before the inlet filter and inlet piping thus not taking into account this pressure drop which is normally anywhere from .2 to .5 PSIA with a relatively clean filter. This can be misleading because performance is calculated on an inlet pressure that is higher than the actual air volume entering the unit resulting in lower output than expected.

ICFM, ACFM and FAD are used interchangeably to reference delivered air. When using published data to run operating performance comparisons it is important to use ICFM or ACFM or FAD consistently. Be clear if inlet pressure is being acquired or estimated.

SCFM (Standard Cubic Feet per Minute) (Nm3/hr) is the CFM at normal inlet conditions of 14.5 PSIA(1 bar), 68° F (20°C), and 0% relative humidity. SCFM can be based on inlet or discharge and it should be specified one way or the other. The most common use is inlet flange measurement.

Operating comparisons should only be evaluated at the same inlet temperature, pressure, relative humidity and cooling water conditions, as well as the same discharge pressure.

A good supplier will want you to specify worst case conditions, i.e. warmest conditions to insure the compressor is capable of meeting the desired output. If you don’t you’ll get the standard design conditions of:

Compressor Pressure Definitions

PSI is a pressure rating which means pounds per square inch.

PSIG is gauge pressure which reads the psi above the ambient or barometric pressure:

PSIA is ambient barometric pressure that varies with the altitude and the weather. This is a very important value when evaluating or estimating any compressor performance; particularly, centrifugal compressors. PSIA is needed to convert ICFM or ACFM to SCFM (M3/hr to Nm3/hr).

Understanding Horsepower and power cost

Motor horsepower – references the nameplate horsepower.

(BHP) Brake Horsepower is the input power required at the compressor input shaft to drive compressor at rated flow and rated pressure.

Input Motor Power in kW – (can be measured or calculated) that generates kWh – the amount of power consumed which drives the power bill. Input motor power is affected by such factors as motor efficiency, power factor, motor conditions, starter and disconnect conditions, power quality and many more.

Specific Power

SCFM (Nm3/hr) is typically the flow rating (projected or measured) for an input kW. With this data, each unit’s specific power in SCFM or Nm3/hr/kW input is calculated. (Note that many manufacturers use BHP/100 cfm.)

BHP/100 cfm does not include the actual operating energy requirement (such as other losses in the couplings, main drive, and controls which increase the projected operating up to 20%).

I hope this guide has explained some of the subtle differences between different air compressor performance measures. If you need help assessing your needs for a new air compressor or having trouble with the performance of an existing unit then give the team at Pye-Barker a call on 404-363-6000 or drop us a line sales@pyebarker.com and we will take care of you.

Manufacturing and processing has seen a boom in compressed air usage over the last decade or so. Devices and controls have become more sophisticated and in turn less tolerant of damp compressed air.

Traditionally, moisture in compressed air was simply tolerated. Despite the fact it can cause trouble in pneumatic systems, solenoid valves and air powered motor

Moisture can also:

How Does Wet Air Affect Different Components of My Compressed Air Systems

The Plant Wide Air System – Dirt, water and oil in your compressed air lines and the inner surfaces of pipes and fittings, can cause an increase in pressure drop resulting in reduced efficiency and higher costs.

Water condenses out of the air and builds up in the system accelerating corrosion and shortening the useful life of equipment. Corrosion particles can accumulate in plug valves, fittings and instrument control lines.

Valves and Cylinders – experience a build-up of sludge which consists of dirt, water and oil in the compressed air. The sludge acts as a drag on pneumatic cylinders so that the seals and bearings need more frequent maintenance intervals. Moisture dilutes the oil required for the head and rod of an air cylinder and can corrode the walls and slows response. Moisture flowing to rubber diaphragms in valves can cause these parts, to stiffen and rupture.

Air Powered Tools – Dirty and wet air will result in sluggish operation, more frequent repair and replacement of parts due to sticking, jamming and rusting of wearing parts. Water also will wash out the required oils, resulting in excessive wear. A decrease in pressure at the tool caused by restricted or plugged lines or parts reduces each tool’s efficiency and effectiveness.

These tools are designed to run on high grade compressed air – make sure your air matches the tool manufacturer’s specifications.

Instrument Air – A small amount of moisture passing through an orifice can cause malfunction of the instrument and the process it controls. Corrosion particles in the air system also can cause damage to instruments and plug their supply airlines.

Instruments and pneumatic controllers in power plants, sewage treatment plants, chemical and petrochemical plants, textile mills and general manufacturing plants, all need clean, dry air for efficient operation.

Preservation of Products – When used to mix, stir, move or clean a product, air must be clean and dry. Otherwise you risk damaging or contaminating the product. Moisture in control line air can cause the wrong mixture of ingredients in a bakery, the incorrect blend in liquor, waterlogged paint, or ruined food products.

As you can see moisture contamination in your compressed air can lead to all sorts of problems for your compressed air system. Getting the right dryer(s) installed can go a LONG way towards minimizing your down time and maximizing the length and quality of life of your compressed air processed and equipment.

If you are experiencing too much down time, intolerably high maintenance bills or just think you might be paying too much for your compressed air then give the team at Pye-Barker a call on 404-363-6000 or drop us a line sales@pyebarker.com. We can guide you through cutting your compressed air costs in any number of ways.

Contamination of products, disrupted manufacturing processes… physical erosion of your compressed air system. Any of these can reduce the profitability of your plant. A steady supply of ‘commercially dry’ compressed air is vital to keeping quality of products high, maintenance costs as low as possible and preventing lost productivity through downtime.

Within the dryer market there are four categories – Chemical, Refrigerated, Membrane and Regenerative Desiccant.

Regenerative desiccant dryers use adsorbents to take moisture out of the compressed air when at pressure, then once they are full the adsorbent is regenerated at low pressure. Once regenerated the adsorbent media is ready for its next use in the dryer.

This article looks at the four different types of Regenerative Desiccant Dryers, one of the more common types of dryer on the market.

Pressure Swing Regenerative Dryers.

The simplest type of dryer. Pressure swing dryers have multiple vessels where the pressure swings between the different vessels so that while one vessel is being used to dry the air the remaining vessels are regenerating their adsorbent.

No attempt is made to retain the heat of adsorption within the desiccant bed. The dryers work on short cycles of between 5 to 10 minutes before the vessels are switched. The heat adsorbed is used to desorb the moisture in the regeneration phase.

High Pressure Swing Dryers.

At higher pressures air density allows these dryers to dissipate the heat of adsorption before the end of the drying process. In High Pressure Swing Dryers, no attempt is made to retain the heat so it can be used in the regeneration process. These dryers typically operate on a 30 to 60 minute cycle time.

Unheated purge air provides the energy to regenerate the desiccant bed and we see exhaust temperatures as much as 100°F lower than the inlet temperature.

Internally Heated Regenerative Dryers.

Heaters are either clamped to the shells of the desiccant vessels or heating elements are run through the desiccant beds in this class of dryer. These dryers typically operate on four hour cycles. The only problem with internally heated regenerative dryers is desiccant must be changed-out frequently because of the hydro-thermal destruction of the adsorbent at elevated temperatures in moist environments.

Externally Heated Regenerative Dryers.

Externally heated dryers rely on the indirect heating of the wet adsorbent. In this design regeneration can be achieved at either line or atmospheric pressure. Obviously atmospheric pressure is more efficient.

Regenerative desiccant air dryers can be designed and manufactured to almost any service conditions.  Before ordering make sure you review the performance of your dryer against your original design spec in partnership with your provider of choice. Nobody wants wet air!

If you need to upgrade your dryer or install a new compressed air system call the team at Pye-Barker on 404-363-6000 or drop us a line sales@pyebarker.com

There are really only two ways to make a profit in business. Reduce your costs of production or Sell more of your products. The president of your company and your CFO are not doubt admonishing you to cut costs as much as you can.

I’m sure you’ve shared the same mission with your team. One of the biggest opportunities to cut costs is to reduce power consumption. And one of the biggest power users of power in most production plants is:

Your Compressed Air System

Compressed Air System design is a matter of not how much you have but how well you use it. It wouldn’t be uncommon for a business to be able to cut their compressed air demands by 20% just by eliminating leaks.

Beyond that there are opportunities to get the same production for a less costs. (Or create the capacity to scale up and keep your costs constant). Here’s how you can do that

Make Sure Each Piece Of Machinery Is Receiving The Right Pressure.

Unfortunately – when individual pieces of machinery aren’t getting enough air pressure, the maintenance team often just jacks up the air pressure until the complaints go away.

With only a couple of machinery operators complaining, if maintenance increases the system pressure – then it’s a given that a lot of other machinery is going to be receiving too much air.

Best practice to avoid this problem is to divide your compressed air system into zones and use regulators so that the pressure delivered to each zone matches the demand of the machinery. Depending on the complexity of your compressed air system you might want to engage an external compressed auditor (like Pye-Barker) to help guide you through this process.

After you’ve started to manage your air flow more systematically you’ll reduce your compressed air consumption – slashing your power bills by producing less compressed air.

Invest In Storage

Most compressed air systems like to be running at a constant speed, rather than whipsawing between full-load and unloaded every couple of minutes. Depending on the size of your compressor and the storage capacity of your current system this may not be possible.

When your compressors are flip-flopping between loaded or unloaded they consume a lot of power, and incur a lot of wear and tear. If that is the case it is wise to increase the storage capacity of your system to reduce power bills and break down.

You can do this with either dedicated storage, secondary storage or even offline high pressure storage.

Optimize Air Usage

Bearing in mind that it takes between 7 and 8 horsepower to deliver one pneumatic horsepower, it might pay to switch some of your air driven machinery out for more energy efficient options and use less compressed air. For example you might be able to:-

In the end the cost of a unit of compressed air is relatively static. The value you get from your investment in your compressed air is determined by how efficiently you use the air your produce. This is why compressed air auditing is essential for any business running complex compressed air systems. This advice goes double if you are considering adding more compressors to your system to accommodate ‘increased demand.’

There are always opportunities to improve your compressed air system and bring your costs into line with best practices. If you are considering investing in more air compressors or are looking to cut costs I’d recommend starting with an AirInsite compressed air audit. To arrange yours call 404-363-6000 or drop us a line sales@pyebarker.com and we can get the ball rolling.

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Savannah Office Address:
1105 Louisville Rd
Savannah, GA 31415
TEL: (912) 238-0303
FAX: (912) 238-5214
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121 Royal Dr.
Forest Park, GA 30297
TEL: (404) 647-0986
FAX: (404) 361-8579
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