Author: Neal Raker

Double-Acting Reciprocating Air Compressors: What They Are, Where They Fit, and Why Industry Still Chooses Them

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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 tools, helps run automated equipment, and supports processes that need clean, controlled air. There are lots of ways to make compressed air, but one of the most common “workhorse” designs is the reciprocating compressor—think of it like a mechanical bicycle pump that runs on a motor. In this post, we will focus on a specific version: the double-acting reciprocating air compressor.

What is a double-acting reciprocating air compressor?

A reciprocating air compressor uses a piston moving back and forth inside a cylinder to squeeze air into a smaller space (that is what makes the pressure go up). The “double-acting” part means it squeezes air on both sides of the piston—so it does useful work on the forward stroke and on the return stroke.

Why it matters: you can usually get more compressed air from the same basic machine size, and the output tends to be steadier than a single-acting design.

How it works (in plain language)

  1. It pulls air in. As the piston moves, a valve opens and outside air fills the cylinder.
  2. It squeezes the air. The piston comes back, shrinking the space and raising the pressure.
  3. It pushes the air out. Once the air is at a higher pressure than the system, another valve opens and the compressed air flows out.
  4. It repeats on both sides of the piston. In a double-acting design, one side is working while the other side is also taking a turn—so more of the motion becomes useful compression.

When a site needs higher pressure, reciprocating compressors are often built in stages—basically, the air gets squeezed a little, cooled down, then squeezed again. Cooling matters because air heats up when you compress it. In real installations, the compressor is usually part of a whole “compressed air system” that can include storage (an air receiver tank), cooling, drying, and filtration depending on how clean and dry the air needs to be.

How double-acting reciprocating compressors are used

You will find double-acting reciprocating compressors in places that need dependable air, especially when pressure needs are higher, or when demand goes up and down a lot during the day. Common examples include:

  • General plant air for tools, equipment, and production support—especially when the facility wants higher pressure.
  • Controls and automation (after proper drying/filtration) where steady, reliable air helps equipment behave predictably.
  • Work that comes in bursts, for example, operations that run hard for a while, then slow down—where a reciprocating machine can be a good match.
  • Job sites and temporary setups (often smaller reciprocating units), like maintenance work or seasonal blowouts.
  • Backup duty when a facility wants a second, dependable air source ready to step in.

Why industry chooses them: the “unique factors”

  • They can manage higher pressures. If the job calls for “more push,” this design is often on the shortlist.
  • Double acting = more done per stroke. Because both sides of the piston compress air, you get more output from the same basic motion.
  • They are a good fit when demand is not steady. Many sites do not use the same amount of air every minute of the day. Reciprocating machines can be controlled to respond to those changes.
  • They are built to be maintained. These compressors are known for being serviceable; parts that wear can be replaced, and the machine can keep going for a long time with proper care.
  • They match well with a “complete system.” Pairing the compressor with storage tanks, dryers, and filters can make the whole air system smoother and more dependable.

Where it fits vs. rotary screw compressors

If you have ever investigated industrial compressors, you have probably seen rotary screw compressors mentioned a lot—and for good reason. They are popular for steady, all-day air demand. Double-acting reciprocating compressors tend to shine when you need higher pressure, when air demand swings up and down, or when you want a machine that is very “mechanical” and service-friendly.

Quick selection checklist (rules of thumb):

  • Pick double-acting reciprocating when you need higher pressure, your air use changes a lot, and you value a design that can be maintained and rebuilt over time.
  • Pick rotary screw when you need lots of air, continuously, and you expect long run hours at a steady load.
  • Either way, remember: the compressor is only part of the story. Storage tanks, piping leaks, dryers, and filters can make a substantial difference in performance and cost.

Bottom line

A double-acting reciprocating air compressor is a classic workhorse: it uses a piston to compress air, and it does that work on both strokes. That simple idea—getting useful compression on the way out and the way back—helps explain why this design is still common in demanding industrial settings.

Neal Raker, Application Engineering Manager

nealraker@exair.com

New ATEX EasySwitch® Wet-Dry Vac: Safer Industrial Cleanup in Explosive Environments

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A pneumatic, ATEX-rated wet/dry vacuum built for Zones 1 and 21—switching between dry debris and liquid recovery in seconds.

EXAIR ATEX EasySwicth Vac for explosive environments.

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

The Human Side of Safety: Why EXAIR’s Certifications Are Your True Safety Net

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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

Chip Trapper: Take Back Control of Your Coolant, and Your Productivity

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If you work with CNC machines, lathes, or other equipment that uses coolant or cutting fluids, you already know the headache that comes with chip‑laden, contaminated liquid. Floating debris, sludge, and swarf don’t just affect coolant life—they cause machine downtime, poor finishes, pump damage, and unnecessary costs.

The EXAIR Chip Trapper™ and High Lift Chip Trapper™ are designed to eliminate these problems quickly, safely, and without the mess or maintenance headaches of traditional pump or electric vac systems. Here’s how this powerful solution helps you reclaim time, money, and consistency on your shop floor.

Clean Your Coolant—Fast and Without the Mess

The Chip Trapper uses EXAIR’s Reversible Drum Vac, a simple but powerful two‑way pump that quickly vacuums contaminated coolant into a standard 55‑gallon drum. As the liquid enters the drum, it’s forced through a durable, reusable filter bag that traps chips and debris before the clean liquid is pumped back out.

How this benefits you:

  • Cuts coolant replacement costs by removing chips instead of throwing away usable fluid.
  • Prevents pump failures caused by recirculating metal chips and fines.
  • Reduces machine downtime—you can restore coolant clarity in minutes instead of hours.
  • Improves machining performance by keeping cutting fluid clean and flowing as intended.
  • You have options – You can pick what level of filtration that you want to achieve from 1 micron to 200 microns with additional, replacement filter bags. Systems come standard with 5-micron filtration.

Built for Real Shop Conditions

Your environment is demanding, so the equipment has to be too. The Chip Trapper is engineered for durability, reliability, and easy operation in any industrial setting.

Key features your team will appreciate:

  • Runs on compressed air—no electric motor, no moving parts to fail.
  • Works with your existing shop air up to 100 PSIG, with a maximum of 120 PSIG.
  • Designed for years of maintenance‑free performance when used with clean, filtered air.
  • Automatic safety shutoff prevents messy overfilling.
  • Quick‑change filter bags make maintenance simple and efficient—no tools required.

Because the system has no electrically driven parts, it’s not only safer—it avoids the clogs, burnout, and unreliability of conventional electric pumps.

Easy Operation: Vacuum In, Pump Out

Using the Chip Trapper is refreshingly simple:

  1. Connect compressed air using the manual shutoff valve.
  2. Attach the vacuum hose and chip wand to pull liquid and debris from your sump.
  3. Set the directional valve to FILL to vacuum dirty liquid.
  4. Set the valve to EMPTY to pump back out filtered, clean coolant.

Most users love that the process is clean, fast, and nearly foolproof—no dealing with clogged pumps or slow draining.

Handles Even Tough Applications

The Chip Trapper isn’t just for coolant recycling—it’s an incredibly versatile cleanup tool.

Great for:

  • CNC sump cleaning
  • Removing chips from settling tanks
  • Floor spill recovery (with optional Spill Recovery Kit Model 6901)
  • Deep sumps or long fluid runs (High Lift Chip Trapper models offer increased suction for these situations)

Whether you’re cleaning up after heavy machining or maintaining multiple machines, the Chip Trapper keeps your shop safer, cleaner, and more productive.

Low Maintenance, High Reliability

Maintenance is minimal and quick:

  • The safety shutoff float may occasionally need cleaning with mild solvent/detergent.
  • The stainless‑steel pump can be disassembled for deeper cleaning if needed.
  • Vacuum hose and attachments rinse clean after each use.

Because clean air is critical, EXAIR recommends a 10‑micron filter separator for the compressed air supply—when used properly, the unit will run for years without issue.

The Bottom Line: A Cleaner Shop and a Healthier Bottom Line

The Chip Trapper is more than a coolant-cleaning tool—it’s a reliability booster, money saver, and productivity enhancer.

Customers typically see:

  • Significantly longer coolant life
  • Better machine performance
  • Reduced labor time for sump cleaning
  • Lower maintenance costs
  • A safer, cleaner work environment

If your machines are struggling with chip buildup, cloudy coolant, or recurring sump issues, the Chip Trapper is one of the simplest, most cost‑effective upgrades you can make for these processes.

Get yours today. EXAIR ships orders for Chip Trappers within 1 business day after receipt of order. They are available with a 30-day guarantee, so there is zero risk on your part. You can check out more about operational specifications here.

Do you have questions?  Please contact one of our Application Engineers. They can help you determine if the Chip Trapper is right for your application.

Neal Raker, Application Engineering Manager
EXAIR