Author: Al Wooffitt

The Smartest Way to Stop Wasting Compressed Air

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The most efficient way to use compressed air is simple: turn it off when you don’t need it. While engineered blow-off tools drastically lower utility demands, running them continuously across empty conveyor belts or during line pauses still drains valuable factory resources. The EXAIR Electronic Flow Control (EFC) eliminates this waste by pairing a precision photoelectric sensor with an advanced timing control module.

By automatically shutting down the air supply the moment a part passes, the EFC limits compressed air consumption strictly to active processing windows. This plug-and-play optimization system integrates directly into existing lines without complex PLC programming or wiring, offering a direct path to slashing energy bills.

Core Operational Benefits of the EXAIR EFC

Implementing automated flow regulation provides immediate operational improvements:

  • Drastic Cost Reductions: Shutting off air during gaps between parts can easily reduce air consumption by 50% to 75% or more, frequently generating thousands in annual factory utility savings.
  • Plug-and-Play Simplicity: The standalone system features a pre-wired NEMA 4 / IP66 polycarbonate enclosure, a 9-foot power cord, and a universal 100-240VAC electrical input.
  • Industrial-Grade Reliability: The compact sensor resists water and dust, boasts superior immunity to electrical noise, and accurately identifies targets up to 3 feet (1 meter) away.
  • 8 Versatile Timing Modes: An integrated analog timer supports eight distinct operations—including on/off delays, flickers, intervals, and “one-shot” pulsing—with time constraints adjustable from 0.10 seconds up to 120 hours.
  • Scalable Flow Ranges: Available across four distinct model sizes to efficiently regulate lines from 40 SCFM up to 350 SCFM via rugged, high-capacity solenoid valves.

Two Automated Applications: The EFC in Action

The true utility of the EFC is unlocked when paired with EXAIR’s Intelligent Compressed Air product family. Below are three common plant configurations utilizing the EFC alongside different EXAIR tools to optimize production.

1. Intermittent Part Drying with the Super Air Knife

When washed parts travel down a conveyor with uneven gaps between batches, running a continuous air stream wastes significant energy.

  • The Setup: A Super Air Knife is mounted over the conveyor line, plumbed through the EFC’s solenoid valve. The photoelectric sensor is positioned just upstream of the knife.
  • The Operation: The EFC is set to Signal On/Off Delay mode. When a part triggers the sensor, the solenoid instantly opens, unleashing a uniform sheet of laminar air to sweep moisture away. As soon as the part clears the sensor, the timer counts down a brief delay to finish the wipe, then snaps the valve shut until the next part arrives.

2. Automated Hopper Replenishment with the Line Vac

Line Vacs can convey many things.

Keeping raw materials flowing into a molding hopper manually can lead to structural overflows or costly machine starvation.

  • The Setup: An air-operated EXAIR Line Vac is installed to convey bulk plastic pellets or grains directly into a manufacturing hopper. The EFC photoelectric sensor is positioned at a designated low-level threshold inside the hopper wall.
  • The Operation: The EFC uses an Inverse Sensing or Delay profile. When the product drops below the sensor line, indicating the hopper is nearly empty, the EFC opens the solenoid valve to power the Line Vac. The vacuum transfers materials smoothly until the timer reaches its preset fill duration (or a secondary high-level sensor is cleared), halting the air supply precisely when replenishment completes.

Stop Paying for Empty Space

Relying on continuously running blow-offs means your plant is actively paying to compress air that blows into empty space. Integrating the EXAIR Electronic Flow Control lets you transition from costly manual oversight to true, targeted automation.

Ready to figure out exactly how much you can save? Check the EXAIR EFC Savings Calculator to input your plant’s specific cycle times, calculate your exact payback period, and start optimizing your workspace efficiency.

Al Wooffitt
Application Engineer

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Beat the Heat: Why EXAIR Cabinet Coolers are the Ultimate Industrial Fix – (Cabinet Cooler Promo)

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As the mercury rises, industrial facilities face a familiar foe: heat-related downtime. When sensitive electronics and control panels overheat, production grinds to a halt—often at the most inconvenient times. While fans or traditional air conditioners might seem like the go-to solutions, they often bring their own headaches, like clogged filters or mechanical failures.

Enter EXAIR Cabinet Cooler Systems, a low-cost and highly reliable alternative that uses nothing but compressed air to keep your critical components running cool and clean. And now through the end of August, with the purchase of these systems, you will receive a free AC Sensor — Model 7929.

How They Work: The Power of the Vortex

At the heart of every EXAIR Cabinet Cooler is a Vortex Tube. This clever piece of engineering converts a standard supply of compressed air into two streams: one hot and one cold.

  • Cold Air Injection: The cold air is discharged directly into the cabinet through a distribution kit, creating a pressurized environment.
  • Contaminant Exclusion: Because the cabinet is slightly pressurized, outside air—along with its dust, dirt, and oil—can never get in.
  • Heat Exhaust: The warm air inside the cabinet is displaced and vented out through the cooler body, leaving your electronics in a clean, temperature-controlled environment.

Maintenance-Free Reliability

One of the biggest advantages of EXAIR’s design is what it doesn’t have. There are no moving parts to wear out, no filters to clog, and no refrigerants (like Freon) to leak.

  • Simple Installation: These units can be installed in minutes through a standard electrical knockout.
  • Long Lifespan: With a clean, dry supply of compressed air, these coolers can run for decades—some have even been tested to work perfectly after 20 years of service.

Smart Cooling with Thermostat Control

While the coolers are incredibly effective, using compressed air continuously can be expensive. To maximize efficiency, most systems include a Thermostat Control.

  • Automated Operation: The thermostat (factory set at 95°F) acts as an on/off switch, activating the cooler only when the temperature reaches critical levels.
  • Digital Precision: For even tighter control, Electronic Temperature Controls (ETC) are available to maintain a constant temperature with a digital LED display.

A Solution for Every Environment

No two facilities are the same, which is why EXAIR offers several ratings to match your specific needs:

  • NEMA 12 (IP54): For dust-tight, oil-tight indoor industrial environments.
  • NEMA 4 (IP66): For splash-resistant indoor or outdoor use.
  • NEMA 4X: Corrosion-resistant 303 or 316 stainless steel for food service or aggressive chemical settings.
  • Hazardous Locations (HazLoc/ATEX): Specifically designed and certified for explosive environments containing gases or dust.
  • High Temperature Models: Capable of providing relief in ambient temperatures reaching up to 200°F (93°C).
Both the HazLoc (left) and ATEX Cabinet Cooler Systems are available from stock in NEMA 4 and NEMA 4X ratings.

Stop the Shutdowns

Don’t wait for a 100°F day to realize your cooling is insufficient. You can use the Cabinet Cooler System Calculator on EXAIR’s website to find the exact cooling capacity you need, with models ranging from 275 to 5,600 Btu/hr.

Al Wooffitt
Application Engineer

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Banner image: Image by stux from Pixabay

Taming Harsh Environments: The Power of EXAIR’s PVDF Super Air Knives

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Industrial blow off, drying, and cooling applications are tough. When your processes involve extreme chemicals, aggressive rinses, or highly corrosive atmospheres, standard aluminum or stainless steel hardware can discolor, degrade, or fail entirely.

EXAIR‘s PVDF Super Air Knives provide the ultimate solution for severe environments, combining Intelligent Compressed Air efficiency with the extreme chemical resistance of Polyvinylidene Fluoride (PVDF). These engineered tools deliver a high-velocity, uniform sheet of laminar airflow to eliminate moisture and debris while easily handling both low and high pH exposures.

The PVDF Advantage: Built for Aggressive Chemistry

PVDF is an advanced fluoropolymer engineered for environments where other metals degrade. EXAIR constructs these specialized knives using PVDF bodies paired with Hastelloy bolts to maximize corrosion defense.

  • Extreme Chemical Defense: Highly resistant to aggressive acids, halogenated solvents, and severe caustics.
  • pH Spectrum Versatility: Excellent performance on both ends of the pH spectrum, including direct exposure to brutal compounds like Sodium Hydroxide.
  • Zero Discoloration: Unlike metal alternatives that suffer surface rust or pitting, PVDF maintains its structural integrity and finish over time.

Unmatched Super Air Knife Performance

The PVDF version inherits all the award-winning performance benefits that make the EXAIR Super Air Knife line an industry benchmark:

  • 40:1 Air Amplification: For every 1 part of expensive compressed air used, the knife draws in 40 parts of “free” ambient room air using the Coanda effect.
  • Drastic Energy Savings: Reduces compressed air consumption by up to 80% to 90% when compared to inefficient open pipes or drilled tubes.
  • Whisper-Quiet Operation: Operates at a quiet 69 dBA even at 80 PSIG, protecting workers and ensuring OSHA noise compliance.
  • Laminar Uniformity: Produces a perfectly balanced, hard-hitting line of air across the entire length, eliminating the dead spots common with drilled pipe manifolds.

Size Options and Customization

While metal EXAIR Super Air Knives span up to 108 inches, the stock PVDF Super Air Knives are available in lengths ranging from 3 to 54 inches. Because industrial footprints vary, EXAIR engineers can also machine Custom Super Air Knives at specific metric or imperial lengths tailored to unique application spaces.

Tuning and Fine-Adjustments

Every unit ships with a standard 0.002-inch shim installed to set the initial airflow gap. To scale your force up or down, you can use specialized Super Air Knife Shim Sets.

PVDF Super Air Knife Kits include the Air Knife itself (PVDF body, Hastelloy C-276 hardware, and PTFE Shims,) a PTFE Shim Set, an Automatic Drain Filter Separator, and Pressure Regulator.

Tech Tip: Because PVDF is a softer polymer material than aluminum or steel, it requires a unique, careful tuning approach during installation to achieve the exact airflow pattern required. You can view step-by-step guidance on the EXAIR Blog video guide for changing PVDF shims.

For complete system installations, pairing the knife with EXAIR Super Air Knife Kits—which include an automatic drain filter separator and a pressure regulator—enables easy input pressure dialing to achieve the exact blowoff impact needed.

If you are ready to swap out loud, corrosive-damaged open pipes for a quiet, highly efficient, and chemical-resistant alternative, contact an EXAIR application engineer to configure the perfect PVDF setup.

Al Wooffitt
Application Engineer

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Precision Coverage in Tight Spaces: The EXAIR PowerStream Nozzle

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In industrial manufacturing, bigger isn’t always better… especially when you’re dealing with precise liquid application in cramped quarters. EXAIR’s PowerStream Liquid Atomizing Nozzles are designed to solve the common headache of achieving uniform liquid distribution without the need for bulky equipment or a compressed air source.

What Makes PowerStream Nozzles Different?

Unlike standard nozzles that might produce a messy, uneven spray, the PowerStream uses a “liquid-only” design. It operates simply by forcing pressurized liquid against a precision-tuned, angled surface. This creates a deflected flat fan pattern at a 75° angle from the nozzle orientation, essentially forming a “water curtain” or sheet of liquid.

Key Performance Benefits

  • Clog-Resistant Design: Perfect for environments where you might be spraying slightly viscous fluids or liquids containing small particulates.
  • No Compressed Air Needed: Because it relies solely on liquid pressure (up to 250 PSI), it’s an energy-efficient alternative for applications where compressed air is unavailable or unnecessary.
  • Rugged Construction: Built from Type 303 stainless steel, these nozzles are ready for harsh, corrosive environments and can withstand temperatures up to 800°F (426°C).
  • Compact 1/8 NPT Footprint: As EXAIR’s smallest liquid-only nozzle, it fits into tight spots where other spray solutions simply can’t reach.

Ideal Applications

The PowerStream Nozzle is a versatile workhorse for general-purpose industrial tasks, including:

  • Cleaning & Rinsing: Washing vegetables, rinsing conveyor belts, or applying detergents.
  • Cooling & Quenching: Spraying water or light oils onto hot parts during production.
  • Dust Suppression: Creating a fine curtain of liquid to capture airborne particles.
  • Coating: Applying even layers of rust inhibitors, lubricants, or dyes.

Specifications at a Glance

FeatureDetails
MaterialType 303 Stainless Steel
Thread Size1/8 NPT
Max Pressure250 PSI
Spray Pattern75° Deflected Flat Fan
Flow Rates5 distinct models (0.15 to 1.84 GPM)

Expert Support

If you are unsure whether a liquid-only or an air-atomizing nozzle is right for your project, our Application Engineering team is available to help you dial in the exact flow rate and pattern needed for your specific process.

Al Wooffitt
Application Engineer

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