Author: Jordan T Shouse

EXAIR Cabinet Cooler vs. Refrigerant-Based Panel Coolers: Which Is Right for Your Application?

Published on by Jordan T ShouseLeave a comment

Keeping electrical enclosures cool is essential for protecting components, avoiding downtime, and maintaining consistent performance. While both Cabinet Coolers and refrigerant-based panel air conditioners can get the job done, more manufacturers are shifting toward a simpler, more reliable solution like Cabinet Coolers from EXAIR.

Here’s a closer look at how they compare—and why Cabinet Coolers often come out ahead in real-world industrial environments.

What Is a Cabinet Cooler?

Compressed air goes in; cold air comes out of the Vortex Tube and is circulated through the enclosure. The Vortex Tube’s hot flow and the warm exhaust from the enclosure are vented through the Cabinet Cooler’s body.

What Is a Cabinet Cooler?

Cabinet Coolers use compressed air and a vortex tube to create a stream of cold air that circulates inside the enclosure. With no moving parts and a straightforward design, they offer dependable cooling without the complexity of traditional systems.

Why EXAIR Cabinet Coolers Stand Out:

  • Maintenance-free operation
  • No moving parts to fail, leading to long life
  • Compact, lightweight design
  • Installs in minutes
  • Thermostat control options to minimize air use

What Is a Refrigerant-Based Panel Cooler?

Refrigerant-based panel coolers function like a traditional air conditioner, using a compressor and refrigerant to remove heat from the enclosure.

While effective, they introduce added complexity—both in installation and long-term upkeep.

Where Cabinet Coolers Have the Advantage

1. Simplicity That Saves Time

Refrigerant systems require wiring, mounting, and clearance for airflow. Cabinet Coolers, on the other hand, install quickly through a standard knockout and are ready to run with minimal setup.

For operations that can’t afford long installation windows, this simplicity is a major advantage.

2. Virtually Zero Maintenance

One of the biggest hidden costs of refrigerant systems is maintenance—filters clog, fans wear out, and compressors eventually fail.

Cabinet Coolers eliminate those concerns entirely. With no moving parts, there’s nothing to service, replace, or break down.

3. Built for Harsh Environments

Industrial environments aren’t always clean. Dust, oil mist, humidity, and washdowns can quickly degrade traditional panel A/C units.

Cabinet Coolers excel here:

  • No ambient air is pulled into the enclosure
  • Sealed design keeps contaminants out
  • Performs reliably in dirty, wet, or high-vibration conditions

This is where many refrigerant-based systems struggle—and where Cabinet Coolers consistently prove their value.

4. Reliable, No-Downtime Operation

When a refrigerant unit fails, cooling stops—and repairs can be costly and time-consuming.

Cabinet Coolers offer a more rugged, dependable alternative. Their simple design means fewer failure points and more consistent performance over time. Cabinet cooler systems bought over 20 years ago are still in operation to this day.

5. Ideal for Targeted & Intermittent Cooling

Not every application needs a large, continuously running A/C unit. For moderate heat loads or intermittent cooling needs, Cabinet Coolers provide efficient, on-demand cooling—especially when paired with a thermostat control.

Where Refrigerant Systems Still Fit

To be fair, refrigerant-based panel coolers do have their place—particularly in applications with:

  • High, continuous heat loads
  • Large enclosures requiring significant BTU capacity
  • Environments where compressed air is limited or costly

But in many industrial settings, those conditions don’t outweigh the added complexity and maintenance burden. Not to mention the cost to repair and replace after a few years of service.

The Bottom Line

If your priority is reliability, low maintenance, and years of performance in tough environments, Cabinet Coolers from EXAIR offer a clear advantage.

They’re simple to install, built to last, and designed to keep your enclosures cool without the headaches that come with traditional refrigerant systems.

For many manufacturers, that combination isn’t just convenient—it’s a smarter long-term investment.

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.

How Pressure Regulators Help You Save Compressed Air (and Money)

Published on by Jordan T ShouseLeave a comment

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.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

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

4 Mistakes Plants Might Be Making with Compressed Air (and How to Avoid Them)

Published on by Jordan T ShouseLeave a comment

Compressed air is one of the most versatile and expensive utilities in any plant. It powers tools, moves products, cools processes, and keeps production running smoothly. But it’s also one of the most commonly misused resources on the floor.

Small inefficiencies add up quickly, and many facilities are losing thousands of dollars a year without realizing it. The good news? Most of these issues are easy to fix once you know where to look, especially with engineered solutions from EXAIR.

Here are four of the most common mistakes plants make with compressed air, and how to avoid them.

1. Using Open Pipes Instead of Engineered Nozzles

The Mistake:
Blowing with open pipes or drilled tubes is still surprisingly common. It “kinda works,” but it’s incredibly inefficient, noisy, and unsafe.

Why It Matters:
Open pipes consume a massive amount of compressed air and can create dangerous dead-end pressure situations. They also produce high noise levels that can exceed OSHA limits.

How to Avoid It:
Switch to engineered air nozzles and knives like EXAIR’s Super Air Nozzles or the Super Air knife. These are designed to:

  • Reduce air consumption by up to 80%
  • Meet safety standards for dead-end pressure
  • Dramatically lower noise levels

The Result:
Immediate air savings, safer operation, and a quieter plant floor.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

2. Running at Higher Pressure Than Necessary

The Mistake:
Many plants run their systems at higher pressure “just in case.” It feels safer—but it’s costing you.

Why It Matters:
Every 2 PSI increase in pressure can increase energy consumption by roughly 1%. Multiply that across your entire system, and the cost adds up fast.

How to Avoid It:
Use EXAIR’s pressure regulators to optimize pressure at the point of use instead of over-pressurizing the entire system.

The Result:
Lower energy bills and better control over your applications—without sacrificing performance.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

3. Ignoring Compressed Air Leaks

The Mistake:
Leaks are often treated as “minor” issues and left unresolved.

Why It Matters:
Leaks can waste 20–30% of your compressed air output. That’s essentially money leaking out of your system 24/7.

How to Avoid It:

  • Conduct routine leak audits using the Model 9207 Ultrasonic Leak Detector
  • Fix worn fittings, hoses, and connections
  • Use efficient components that minimize unnecessary air use

Pairing leak reduction with efficient products from EXAIR ensures you’re not just fixing losses, you’re preventing new ones.

The Result:
Reduced compressor load, lower maintenance costs, and immediate energy savings.

4. Not Optimizing Airflow for the Application

The Mistake:
Using too much air—or the wrong type of airflow—for blowing, drying, or conveying applications.

Why It Matters:
Inefficient airflow leads to higher consumption, inconsistent performance, and unnecessary wear on equipment.

How to Avoid It:
Adopt engineered air amplification products like EXAIR’s Air Knives, Air Amplifiers, and Air Wipes. These devices entrain the surrounding air to:

  • Maximize output while minimizing compressed air use
  • Provide uniform, high-performance airflow
  • Improve drying, cleaning, and conveying efficiency

The Result:
Better process performance with significantly lower air usage.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Compressed air is too valuable to waste. The difference between an optimized system and an inefficient one often comes down to a few overlooked decisions.

By avoiding these common mistakes—and implementing engineered solutions from EXAIR—plants can:

  • Cut energy costs
  • Improve safety
  • Boost productivity
  • Extend equipment life

If your facility hasn’t evaluated its compressed air usage recently, now is the time. Even small changes can deliver fast, measurable results.

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.

Receiver Tanks: Why They Matter and How to Size Them for Compressed Air Systems

Published on by Jordan T ShouseLeave a comment

In many compressed air systems, receiver tanks are an overlooked component. While compressors and end-use devices often get the most attention, a properly sized receiver tank can dramatically improve system performance, efficiency, and reliability—especially when operating compressed air devices such as those from EXAIR.

Understanding why receiver tanks are important and how to size them can help prevent pressure fluctuations, reduce compressor cycling, and ensure that air-powered devices like vortex tubes, air amplifiers, and air knives operate at their optimal performance.

What Is a Receiver Tank?

A receiver tank (also called an air receiver) is a storage vessel that holds compressed air before it is delivered to the system. It acts as a buffer between the compressor and the demand side of the system.

Think of it as a shock absorber for compressed air demand. When demand spikes suddenly, the receiver tank supplies stored air, so the compressor does not need to instantly ramp up.

Why Receiver Tanks Are Important

1. Stabilizing System Pressure

Many compressed air applications—especially precision devices like those from EXAIR—perform best when the supply pressure remains stable. Without a receiver tank, short bursts of demand can cause pressure drops that reduce device effectiveness.

2. Reducing Compressor Cycling

Frequent compressor starts and stops can:

  • Increase energy consumption
  • Increase wear on compressor components
  • Reduce system reliability

Receiver tanks provide stored compressed air, allowing the compressor to run fewer but longer cycles, which improves efficiency.

Basic Receiver Tank Sizing

Receiver tanks are typically sized based on:

  • Compressor output (CFM)
  • System pressure range
  • Allowable pressure drop
  • Duration of air demand spikes

A commonly used rule of thumb:

3–5 gallons of receiver capacity per CFM of compressor output

Example:

Compressor output: 100 CFM

Recommended receiver tank:

  • 300–500 gallons

However, for systems with intermittent high-flow devices like air knives or amplifiers, additional storage may be beneficial.

Receiver Tank Calculation Example

A more precise calculation can be used when determining storage needed for peak demand.

Formula:V=T×C×PaP1−P2V = \frac{T \times C \times P_a}{P_1 – P_2}V=P1​−P2​T×C×Pa​​

Where:

  • V = receiver volume (cubic feet)
  • T = time (minutes) air is needed
  • C = air demand (SCFM)
  • P₁ = maximum system pressure (psia)
  • P₂ = minimum system pressure (psia)
  • Pₐ = atmospheric pressure (14.7 psia)

Example Scenario

An application uses:

  • EXAIR Super Air Knife
  • Air demand: 60 SCFM
  • Peak usage duration: 30 seconds (0.5 minutes)
  • System pressure drop allowed: 100 PSI → 90 PSI

Converted pressures:

  • P₁ = 114.7 psia
  • P₂ = 104.7 psia

Calculation:V=0.5×60×14.7114.7−104.7V = \frac{0.5 \times 60 \times 14.7}{114.7 – 104.7}V=114.7−104.70.5×60×14.7​ V=44.1 cubic feetV = 44.1 \text{ cubic feet}V=44.1 cubic feet

Convert to gallons:44.1×7.48=329 gallons44.1 \times 7.48 = 329 \text{ gallons}44.1×7.48=329 gallons

Recommended receiver tank: ~330 gallons

This ensures the air knife can run for 30 seconds without causing system pressure to drop below the acceptable range.

Where to Install Receiver Tanks

Most systems benefit from two receiver tanks:

Primary Receiver

Located near the compressor.

Purpose:

  • Reduce compressor cycling
  • Provide bulk storage

Secondary Receiver

Located near high-demand equipment like:

  • Air knife stations
  • Blow off systems
  • Cooling devices

This provides localized air storage for equipment like EXAIR compressed air products, preventing pressure drops across long piping runs.

Receiver tanks are one of the simplest and most cost-effective ways to improve compressed air system performance. For facilities using high-performance compressed air products from EXAIR, a properly sized receiver tank ensures these devices operate at their maximum efficiency and effectiveness.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email