Intelligent Compressed Air® Solutions For Industry

My son was complaining about his unusually high water bill. I advised him to look for leaks around the house. Checking for leaks and how to check for them is something that I have been assisting customers with for the last 19 years. Water, compressed air, no difference. A leak is a leak. It did not take me long to find his problem. He had left the water on to a garden hose. Lying in the hot sun, it developed a bulge in the hose that eventually burst.

Leak Detector

With compressed air systems, when pressure loss becomes a problem, the first thing auditors look for are leaks. EXAIR has a handheld ultrasonic leak detector that can find leaks that you may not be able to hear. This instrument detects inaudible sounds emitted from the smallest of leaks.

Having found and fixed all the leaks, the job is not done. Over time, inefficient compressed air devices are added to the system. Air blow off probably is the leading offender and open copper pipe is usually the culprit.


Open pipe not only wastes compress air but it is not compliant to the OSHA dead ended pressure and can also violate sound level exposure requirements. The solution is to install EXAIR engineered nozzles. They can cut operating costs since they use only a fraction of the compressed air of typical blow-offs and comply with the OSHA sound and dead ended pressure directives.

nozzle array

EXAIR has a full range of sizes of engineered air nozzles ranging from the size as small as a grain of rice up to 1 1/4″ NPT. With so many selections you may not know which one to decide on and that is where our application engineers come in. Feel welcomed to give them a call at 1-800-903-9247. They truly would appreciate the opportunity to assist you.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363

Vacuum Generators: Porous Vs. Non-Porous

I had customer call this week who was using an E-Vac model 800008H, an 8 SCFM Porous Vacuum Generator, to pull a vacuum on four vacuum cups.  He was trying to lift a part with the four vacuum cups placed on a clean metal portion of the part.  Unfortunately he was having a little trouble.  He had to lift the product very slowly because the part could easily be dislodged, if the part was bumped or came to an abrupt stop.


EXAIR’s family of In-Line E-Vac vacuum generators

The problem is a relatively simple one.  The customer choose a porous vacuum generator when he would be better served with a non-porous unit.  The vacuum cups are attaching to a non-porous surface, sheet metal, in a relatively clean environment.  The difference between porous and non-porous units is that  porous units has more vacuum flow available at a low vacuum level, where the non-porous vacuum generators have a higher level of vacuum, but less vacuum flow.  Because of the high vacuum flow, a porous unit is much better for lifting porous materials like cardboard, some particle boards, and fabrics.  The higher vacuum flow of porous vacuum generators helps maintain the vacuum when pulling upon materials which let a constant flow of air through. In the customer’s case, he was lifting a clean sheet of metal, a non-porous material, and needed a higher vacuum level as opposed to a higher vacuum flow. A higher vacuum level [more inches of mercury (Hg) of vacuum] would pull harder upon the metal and hold it tighter.

Let’s look at the customer’s example more closely.  An EXAIR model 800008, porous E Vac, will generate a maximum of 21 inches of mercury (“Hg).  A model 810008, non-porous E Vac, will generate 27  inches of mercury (“Hg).  Let say he was using a 900758 3 1/4” diameter round vacuum cup. If you look at the Vacuum Lift Chart, you see that the 900758 can lift 42.8 lbs. at 21 “HG, but it can lift 55.0 pounds at 27 “HG of mercury.  So in this application the customer can increase their lifting capacity by 28.5% by switching from a non-porous vacuum generator to a porous vacuum generator.

Dave Woerner
Application Engineer

Advanced Management of Compressed Air – Storage and Capacitance

Receiver Tank Drawing

Last week I attended the Advanced Management of Compressed Air Systems seminar put on by the Compressed Air Challenge.  For those unfamiliar with the Compressed Air Challenge, it’s an organization focused on delivering reliable and sustainable compressed air that has maximized efficiency.  Many of the industry’s best practices are preached, if not mandated, and the ultimate goal is to reduce compressed air use as much as possible.  This fits in line with EXAIR products, their design for maximum efficiency, and the recurring ability of our customers to reduce their compressed air use by using our products.

The “advanced” seminar dives into compressed air system profiles, explores the math and theory behind system design, explains the various types of system controls, and shows how to balance compressed air supply and demand.  These things are great not only on their inherent value, but also because when Brian Farno, Russ Bowman, and I attended the Fundamentals of Compressed Air Systems seminar, we kept raising our hands asking questions that were “too advanced”.  The material presented here answered many of those questions, and sparked a few new ones.

One of the questions that came to me during the training had to do with the capacitance of a compressed air system.  When storing the energy of a compressed air system in a receiver tank, there has to be a pressure gradient in order for there to be energy storage.  If a receiver tank has the same inlet and outlet pressure, it is merely part of the system plumbing and provides no benefit to the system when demand peaks.  So I thought to myself, “if a pressure drop is needed across a receiver tank to achieve system capacitance, and the capacitance of the system is related to the value of that differential, a system could theoretically be supplied enough compressed air volume with the right pressure specs”.

So, I looked to the formula used for sizing a receiver tank.

V = (T x (C – R) x Pa)/P1-P2


V = Receiver volume in cubic feet

T = Time of the event in minutes (amount of time for which the receiver tank must be able to provide compressed air at the needed rate)

C = Intermittent demand amount (how much flow or “Q”) in CFM

R = Flow into tank during event (through needle valve, spare air in system, etc.) in CFM

Pa = Absolute atmospheric pressure (14.7 PSIA)

P1 = Initial receiver tank pressure (in PSI)

P2 = Final receiver tank pressure (in PSI)

Ok, nothing new there.  First grade stuff.  Plugging in some theoretical values we could say:

T = 1 minute

C = 50 cubic feet per minute

R = 0 cubic feet per minute.  In this example we’ll assume there is no residual compressed air flow and that the receiver tank must deliver all the airflow for the duration of the event.

Pa = 14.7

P1 = 100 PSIG

P2 = 90 PSIG

Using these values, the volume calculates to be 73.5 cubic feet.  But, most receiver tanks are sized in gallons so we can multiply by 7.48 to get the figure in gallons.  (7.48 gallons = 1 cubic foot)  This yields an approximate value of 550 gallons.  In plain terms, for the application above, we would need a 550 gallon receiver tank with an inlet pressure of 100 PSIG and an outlet pressure of 90 PSIG to provide compressed airflow over the needed (1) minute duration.

That’s a big tank.

Now, back to my thought on pressure differentials – if we increase the ΔP, we can decrease the size of the receiver tank.  Let’s say the inlet pressure to the receiver tank can be as high as 130 PSIG (a wet tank, in line before any filters or dryers).  This will quadruple the pressure differential and reduce the size of the tank by 75% to 138 gallons.  Great!

Well, great for a new system, but what about one already in place?  What if the application needs 50 CFM of compressed air flow for 1 minute, and the shop already has a 175 gallon tank.  We can work the equation in reverse to determine the necessary pressure differential that will ensure the system has enough capacitance to sustain the event (approximately 32 PSI).  It’s good to know the math.

As a whole, the seminar was a great success and the presenters proved why they’re experts in the field of compressed air.  We’re not too shabby here at EXAIR either.  If you have an application need, give us a call.

Lee Evans
Application Engineer

What The 30 Day Unconditional Guarantee Can Do For You. And Us.

If you’re reading this, then we must have one thing in common: we’re regular visitors to the EXAIR Blog. I work with these guys, so, odds are, I’ve heard it before I read it (and I want you to know that’s not always a blessing), but I still read them…mainly for the pictures.

This has nothing to do with my blog, but it's just awesome.

This has nothing to do with my blog, but it’s just awesome.

The other day, Brian Farno wrote a great piece on how to use our 30 Day Unconditional Guarantee to “prove out” an application before ordering a custom made (and non-returnable) product. Some folks are hesitant to do this, because they feel bad about taking advantage of us – “gaming the system,” I’ve heard it called. Don’t. It’s still better for both of us than sticking you with something that doesn’t give the desired results, and you can’t return.

I helped a customer a while back with a static elimination application – they were interested in a 102” long Super Ion Air Knife…this was an ideal case where a 96” long unit could be used to test performance. This one turned out even better than anyone expected: they actually got the results they were looking for from the 96” Super Ion Air Knife, so we were all pleased.

Another benefit of the Guarantee is, we get to find out where things DON’T work. This can be just about as valuable as knowing where they DO work. I’ve gained many a potential customer’s trust by being up-front with them, and, if I know what DOES work, I’ll be happy to tell you where you might be able to get it. We all will…we want to be your first call for your compressed air application needs. Try us.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax

Fall, My Favorite Season

As the sun sets lower in the sky and the daylight hours get shorter, we are reminded of the impending  winter season. The good part is this is the most fun season for me. There are falls festivals and cool nights for good sleeping. You do not have to run the A/C or the furnace and we see the benefit in low utility bills.

Static Eliminator Line

Inevitably “Ole Man Winter” will come and put an end to it all and we will have to turn on the furnace. As we heat the air in our homes and places of business, problems with static electricity emerge. In the production environment static charges can wreak havoc with sensors, conveyors, personnel and other products within your process.

EXAIR has an extensive line of static eliminating products. We have Super Ion Air Knives up to 96″ long to provide a flat sheet of ionized air. For more localized treatment we have the Ion Air Cannon and Ion Air Jet.  For manual application there is the Ion Air Gun.

With all the selections available it may be a bit confusing on which product to select.. That is why we have a team of application engineers ready to assist you. Give them a call at 1-800-903-9247.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363


R&D…&D Research & Development Daily


I tend to find myself doing quite a bit of research, whether here at work or at home.   Any time I am looking to buy something or test something I am constantly trying to find out if someone has already done it or if they haven’t, can I get my money back if it doesn’t work. Whenever I am trying something new, I always want to make sure I have all the information and just in case it still doesn’t work, be able to minimize my out of pocket cost in the end.

This is why, when you call EXAIR and ask us for a custom product when you are just trying something out, we offer a stock product first to get a base line.  If the stock product doesn’t exactly fit, say you need a 20.5″ long Super Air Knife, we would recommend to test either an 18″ or 24″ stock Super Air Knife to see if it is a viable option.   Once you have tested the stock length then you can simply let us know, within 30 days from the date of purchase, and return the unit.  Then place the order for the custom product that is exactly what you want.

Special Super Air Knife

Not only do we work with you and try to get you exactly what you need, we also will pull from all the experience that the entire company has to help you figure out what is going to work best for your application.   Not to say we have seen everything and done everything, but we are pretty darn close.

If you have any questions or need help with a research and development project you might be working on, give us a call, email, fax or chat.

Brian Farno
Application Engineer

Try It; You’ll Like It


In my continuing adventures of marriage, my wife and I are looking for a new couch.  We both had previous couches from our individual apartments that aren’t going to make the move with us to the new place.  My couch was purchased on clearance from a warehouse store, and didn’t make it six months before I had to reconstruct the 1X4, staple and glue construction.  The couch is less than comfortable to sit on properly, and it’s color, brown, does not fit into the décor of the living room or any room.  You get the picture.  I spent a tiny amount of money and it held up to a tiny amount of use.  I knew the couch wouldn’t hold up for very long when I bought it, but I definitely got what I paid for, and I will not make that choice again.  For one, I want a couch that is very comfortable.  Second, I don’t want to spend another perfect football Sunday shopping for a couch…(writer realizes his wife reads this)… not that it wasn’t a lovely day!

In her shopping, my wife found a company online that manufactures and designs couches inside the USA and allows you to try out the couch for 365 days before deciding, if you want to keep it.  It is amazing how much better I feel about spending a good amount of money on something I haven’t had a chance to see or feel, when I know I can send it back in a couple of weeks, if it doesn’t work out.  They even have designers that will help you pick out fabric and colors to match your room.

Obviously, this is EXAIR’s model inside the US and Canada.  We have a 30 day unconditional guarantee for you to try out our products.  We do this because we have such faith in our products that once you test the product, you will want to keep our products.  We also do this because we don’t want you to feel hoodwinked after a purchase and feel any buyer’s remorse.  If the product doesn’t live up to your standards, we would rather take it back than leave you with any bad feelings about EXAIR.

Dave Woerner
Application Engineer

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