A few years back, I had the pleasure of working with a machine shop manager who wanted to reduce the compressed air consumption in their facility. They had ten lathes, machining high-tech plastic products, and… More
Priorities of Work
Triage, priorities of work, MoSCoW Method, ABCdE, the list could go on and on. These are all methods to help you prioritize your day. I have blogged about my first career as a field service/training on CNC machines. This was something that I was baptized into. During the day-to-day here at EXAIR, and during GORUCK events, it became solidified in the way I approach almost any project and most of the days.
If you Google or use your favorite search engine for What are Priorities of Work, then you may get a list something like what is shown above. I’ve heard many of these over the years, but it wasn’t until one of the GORUCK events I was doing that it truly sank in that if I am not addressing the appropriate tasks first, then I wouldn’t have time for them later. When I was in machine tool, it meant evaluating all the issues preventing the customer’s machine from operating and making sure the longest lead time parts were ordered first, then the ancillary problems after. The goal was always to get the machine back up and running as fast as possible to get the customer back on schedule.
In endurance events, the priorities are to assess yourself, hydrate, if blister/skin care is needed, take care of those, and consume calories if needed. Then, take off your shoes and socks, lie down, elevate your feet, and sleep. Chatting and socializing can happen during, or it can wait until after.
Optimizing a compressed air blow off, reducing wasted compressed air, and maintaining the existing system can very often get knocked down on your priority list. The fact is, these priorities of keeping production moving and then ignoring subservient tasks can add up over time. This can then be the reason you are not able to keep production moving. That’s why here at EXAIR, we help you with a triaged list of priorities when it comes to maintaining your compressed air system.
The six steps to compressed air optimization are laid out to make it easy to check off the big-ticket items first and put the most back into your system. We can also help every step of the way with just a few clicks. Simply request a chat, reserve a video meeting with an Application Engineer, call, or email.
Brian Farno, MBA – CCASS
National Business Development Manager
BrianFarno@EXAIR.com
@EXAIR_BF
Laminate flooring – Step Up to Protect the Surface
A manufacturer of laminated floor planks was having issues with defects prior to packaging. The planks were made from a high-density fiberboard as the core with a top layer of a picturesque image, then sealed together. They were getting fine material that was stuck on the surface, making them defective. The issue was caused after the cutting process. The fine debris remained on the surface and when the image or the sealing material was applied, it could be seen. They tried wiping, but the solution caused scratches. They tried blowing the surface to clear the debris, but due to the static, it would not fall off easily. They required a good solution to improve the cleaning without slowing the process. EXAIR’s Static Eliminators are a great product for industrial processes like this.
In looking at the process, I recommended two pieces of a model 112242 42” Gen4 Super Ion Air Knife Kit. The planks could come out in two spots or four spots. (Reference photo above) To reduce compressed air usage, they could turn on or off which side is needed. The customer asked about the mounting and compressed air attachments. I mentioned the proper setup for the most effective blowing. As a benefit, I offered a plumbing kit to help with the compressed air connection. The PKI option, or Plumbing Kit Installed, has the proper amount of connection to the Super Ion Air Knife to allow for an even force across the entire knife. I upgraded the model number with the PKI option to a model 112242PKI.
This kit will include the Gen4 Super Ion Air Knife with a PKI, a power supply, a filter, a regulator and a shim set. The Gen4 Power Supply creates both positive and negative ions to remove any type of static. The filter will remove bulk liquids and debris from the compressed air to keep the product clean and to optimize performance. The Regulator is used to control the force. This helps to not overuse the amount of compressed air required for the job. With a regulator, you can make fine adjustments to get the proper amount of air. For coarse adjustments, you can change shims to increase or decrease the force. The customer was happy with the properly sized components to operate a non-contact wiping with the Gen4 Super Ion Air Knives.
Once installed, their defect rate almost dropped to zero. They were very happy with the cleanliness of the planks; they decided to purchase six more units. They could place them in different areas of the lamination line to ensure a clean surface. EXAIR manufactures a variety of Static Eliminator products. If you feel that static is an issue in your process, you can always contact an Application Engineer to help you. For the company above, they were “stepping” high.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
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