A plain-English look at a tough, “old-school” compressor design that still earns its place in modern plants. Compressed air is one of those behind-the-scenes utilities that keeps a lot of everyday industry moving. It powers… More
New ATEX EasySwitch® Wet-Dry Vac: Safer Industrial Cleanup in Explosive Environments
A pneumatic, ATEX-rated wet/dry vacuum built for Zones 1 and 21—switching between dry debris and liquid recovery in seconds.
Industrial cleanup is challenging enough—add potentially explosive atmospheres and the stakes go up fast. In ATEX-classified areas, using the wrong equipment can introduce ignition risks from sparks, heat, or static buildup. That is why EXAIR developed the ATEX EasySwitch® Wet-Dry Vac: a compressed-air-powered system designed to deliver reliable wet and dry cleanup in hazardous environments, including ATEX Zones 1 and 21.
What is the ATEX EasySwitch® Wet-Dry Vac?
The ATEX EasySwitch is a pneumatic (compressed-air-driven) industrial vacuum engineered for hazardous locations. It provides powerful suction for both dry materials (dust, powders, chips, absorbents) and liquids (including coolant), and it is designed to let operators switch between dry vacuuming and liquid recovery quickly using a simple latch mechanism.
Why Pneumatic Matters in Explosive Environments
In environments where explosive gases or combustible dust may be present, controlling ignition sources is critical. Because the ATEX EasySwitch operates solely on compressed air, it avoids many risks commonly associated with electric vacuums.
- No electrical components to create sparks, heat, or motor-related failure points.
- Static-dissipative design with proper grounding to help reduce electrostatic buildup.
- No moving parts in the pneumatic vacuum generator, supporting a low-maintenance design for demanding use.
- Built for ATEX Zones 1 and 21, supporting cleanup needs in hazardous, compliance-driven operations.
One vacuum for wet and dry cleanup
Cleanup needs change quickly on the plant floor. With the EasySwitch system, operators can move from dry debris collection to liquid recovery in seconds—helping reduce downtime when switching tasks. Typical materials include dust, powders, coolant, chips, and absorbents.
Where it fits: hazardous-area industrial cleanup
If operations include combustible dust or flammable atmospheres, a dedicated hazardous area vacuum can be a key part of safe housekeeping. The ATEX EasySwitch is designed to support compliant cleanup in critical environments where maintaining clean workspaces is essential.
Part of EXAIR’s industrial vacuum lineup
The ATEX EasySwitch joins EXAIR’s broader range of industrial vacuum systems built for efficiency and performance, including Reversible Drum Vacs for liquid transfer, Chip Trappers for separating solids from liquids, and Heavy Duty Dry and HEPA Vacs for fine dust collection.
Pricing and next steps
ATEX EasySwitch systems start at $3,900 USD. To learn more about specifications, configuration options, and fit for your application, contact EXAIR at (800) 903-9247 or email techelp@exair.com. More details: https://exair.co/atesv
Neal Raker, Application Engineering Manager
nealraker@exair.com
How Pressure Regulators Help You Save Compressed Air (and Money)
Compressed air is one of the most expensive utilities in any industrial facility; yet it’s also one of the most commonly wasted. Many systems run at higher pressures than necessary, driving up energy costs and increasing air consumption without improving performance.
That’s where EXAIR pressure regulators come in.
What is a Pressure Regulator?
A pressure regulator is a simple but powerful device that controls and stabilizes air pressure delivered to your application. Installed at the point of use, it allows you to “dial in” the exact pressure needed—no more, no less.
Inside the regulator, a spring and diaphragm system automatically adjusts airflow to maintain a consistent downstream pressure, even when supply conditions change.
Why Running at Full Pressure is Costing You
It’s common for compressed air systems to operate at full line pressure—often around 100 PSIG—even when the application doesn’t require it. The problem? Higher pressure directly increases air consumption and energy usage.
For example:
- Reducing pressure from 100 PSIG to 80 PSIG can cut air consumption by nearly 20% and reduce power usage by about 10%.
- Lowering pressure even further at the point of use can deliver 30%+ air savings in certain applications.
In short: if you don’t need the pressure, you’re paying for wasted air.
How EXAIR Pressure Regulators Save Air
1. Control at the Point of Use
Instead of running your entire system at one high pressure, EXAIR regulators let you fine-tune pressure exactly where it’s needed. This ensures each application operates at its optimal setting—not the system maximum.
2. Reduce Air Consumption Instantly
Pressure and airflow are directly related. When you lower pressure, you automatically reduce the volume of compressed air consumed.
A simple adjustment—turning down a regulator—can immediately lower SCFM usage without changing equipment.
3. Improve System Efficiency
Lower pressure reduces the workload on your compressor. In fact, decreasing system pressure can reduce compressor energy consumption by measurable margins, helping extend equipment life and reduce maintenance.
4. Eliminate Overuse and “Set-It-and-Forget-It” Waste
Without regulators, operators often compensate by increasing pressure “just to be safe.” Regulators remove that guesswork by locking in the correct pressure for consistent, repeatable performance.
Real-World Example
Let’s say an air knife application runs at 100 PSIG and consumes 42 SCFM. By reducing pressure to 60 PSIG:
- Air consumption drops to 27.6 SCFM
- That’s a 34% reduction in compressed air usage—with no loss in performance if the application still meets requirements.
Multiply that across multiple applications, and the savings add up quickly.
The Bottom Line
If your compressed air system is running at full pressure everywhere, you’re almost certainly wasting energy and money.
EXAIR pressure regulators provide a straightforward solution:
- Lower pressure where possible
- Reduce air consumption instantly
- Improve overall system efficiency
Sometimes, the easiest way to save compressed air isn’t changing your equipment—it’s simply turning down the pressure.
| Jordan Shouse Application Engineer E: JordanShouse@exair.com O: (513) 671‑3322 F: (513) 671‑3363 A: 11510 Goldcoast Dr Cincinnati OH 45249 www.exair.com Find time on my calendar by scheduling a meeting here. |
Pressure regulator image courtesy of AutomationForum.co via Creative Commons
The Legend of Rudolf Hilsch
It is thought that Georges Ranque, a French inventor, inadvertently discovered a key principle while developing early prototypes during the German occupation of France. These prototypes later attracted the interest of Rudolf Hilsch, a German physicist who was working on low-temperature refrigeration systems for military applications. Although Hilsch improved upon Ranque’s original design, he found that it did not surpass conventional refrigeration methods in achieving lower temperatures. Ultimately, the device became known as the Hilsch tube.
The Hilsch tube was constructed using a pair of modified nuts along with several other components. The horizontal section of the T-shaped fitting contains a specially machined element that fits tightly within the arm, featuring a spiral cross-section on the inside that differs from its external shape. At the spiral’s “step,” a small opening connects to the T’s leg, allowing air to enter through the leg and exit via this opening, creating a spiraling flow. The “hot” pipe measures approximately 14 inches in length with a half-inch internal diameter, and its far end is fitted with a stopcock to control the system’s pressure. In contrast, the “cold” pipe is about four inches long, also with a half-inch internal diameter, and its end that connects to the spiral piece includes a washer with a central hole of roughly a quarter of an inch in diameter. Various washers with different hole sizes can be utilized to adjust the system’s performance.
EXAIR’s Vortex Tube operates by channeling compressed air into a tube where it flows through nozzles positioned tangentially to an internal counter-bore. This innovative nozzle design induces the air to rotate in a vortex at speeds reaching up to 1,000,000 RPM. As the air spins, it makes a 90° turn, allowing a valve at one end to release some of the heated air. The remaining air continues down the tube, losing heat in the process, and ultimately exits through the opposite end as cold air.
Both streams in a Vortex Tube rotate in the same direction and at the same angular velocity, which would typically suggest that the rotational speed of the inner vortex should increase due to the conservation of angular momentum. However, this is not observed in practice. A useful analogy can be drawn from Olympic Figure Skating: when a skater extends her arms, her spinning slows down, but as she pulls them in, her rotational speed increases significantly. In the case of the Vortex Tube, the inner vortex maintains a constant speed because it has lost angular momentum. This loss manifests as heat, which is expelled from the hot side of the tube. Consequently, the inner vortex cools down, allowing the cooled air to be channeled for various industrial applications.
The theory behind the Vortex Tube is applied to standard Vortex Tubes and a range of other products designed with specific features tailored to your needs. EXAIR offers a variety of solutions, including Cabinet Coolers, Cold Guns, Adjustable Spot Coolers, Mini Coolers, and Vortex Tubes, all of which function based on this fundamental principle.
If you have questions about Rudolf Hilsch, or anything regarding EXAIR and our products, please do not hesitate to reach out.
Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk
The Human Side of Safety: Why EXAIR’s Certifications Are Your True Safety Net
On a busy production floor, it’s easy to look at an agency certification—like OSHA, UL, or
CE—as just another piece of administrative paperwork. But at EXAIR, we see them differently. We see them as a promise made to the people who power your business every day.
For your operators, these certifications aren’t just labels; they represent certainty. Here is how our commitment to these standards changes the daily lives of your team.
Preserving the Sound of Life
Constant, high-pitched air noise isn’t just an annoyance; it’s a health hazard. Excessive noise leads to permanent hearing loss, chronic stress, and fatigue that can cause workplace accidents. By engineering our products to meet OSHA 1910.95(a) standards, we ensure your team can communicate clearly and go home without ringing in their ears. It’s about protecting their long-term health, not just hitting a decibel target.
Removing the Risk of “Dead-Ending”
The risk of an air embolism—where high-pressure air enters the bloodstream—is a terrifying reality in industrial environments. Our compliance with OSHA 29 CFR 1910.242(b) means we’ve engineered that danger out of the equation. Our nozzles feature safety relief paths that can never be blocked by a person’s skin while still operating the nozzles at a pressure level that can still deliver forceful blowing results. We believe that a simple cleaning task should never lead to a medical emergency.
Peace of Mind Through Global Compliance
Whether it’s ensuring our electrical products are UL Listed to protect your equipment or maintaining CE and RoHS compliance for our global partners, we handle the technical heavy lifting. This allows you to focus on your production goals, knowing your tools are ethically sourced, environmentally safe, and meet the highest global quality benchmarks.
Success Story Spotlight: Silencing the Shop Floor
One of our favorite examples of these standards in action involves a customer who was struggling with deafening noise levels.
The Human Challenge:
The facility was using open-ended blow-off guns that produced a staggering 104 dBA. For the operators, this meant constant discomfort, heavy ear protection, and high stress. Though the guns were “functional,” the environment they created was unsustainable.
The EXAIR Solution:
The facility replaced their old equipment with 355 EXAIR Soft Grip Safety Air Guns
The Transformation:
- The Sound of Silence: Noise levels dropped to 82 dB – a perceived reduction of over 150% for the human ear.
- Full Compliance: The shop floor immediately met OSHA allowable noise exposure standards, creating a vastly more comfortable environment.
- A Financial Win: Along with the safety boost, the facility saved over $28,500 annually in compressed air costs.
The Outcome:
The operators finally had a workspace where they could focus and stay safe. It’s a perfect example of how choosing the right certified tool doesn’t just improve the bottom line – it improves the work lives of the people who matter most. And that’s what we are all about, solving technical problems with a set of solutions that keep operator safety, health and operational efficiency at the forefront of the process.
Neal Raker, Application Engineering Manager