6 Steps to Optimizing Compressed Air: Turn it Down!!!

TURN IT DOWN!!! My wife screamed at 6:00am the morning of our first NFL Sunday. As a lifelong Cincinnati Bengals fan, it’s been a tradition in our house for me to wake everyone up while blaring Guns N’ Roses “Welcome to the Jungle” first thing in the morning each and every week 1. After 13 years together you’d think she would be prepared for this by now, but I still get her every time.

You may also hear your maintenance manager screaming to turn it down while out in the shop. They’re not talking about music volume. They’re more concerned about the compressed air pressure you’re using.

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked.

Pressure Regulators “dial in” performance to get the job done without using more air than necessary.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, using them to minimize your pressure can result in dramatic savings to your costs of compressed air. As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down to the pressure to any compressed air operated product.

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

YouTube. (2009). YouTube. Retrieved September 21, 2022, from https://www.youtube.com/watch?v=o1tj2zJ2Wvg.

How to Identify Your Vortex Tube Model Number

Not a day goes by that we don’t receive a call from a customer that is having trouble identifying an EXAIR part. Due to the robust nature of our Vortex Tubes, they can be installed in applications for many years without any maintenance. When the time comes to expand that line, the labels may have worn off, the unit may be covered in grime or oil, or the personnel that originally ordered the product may no longer be with the company. In any case, one of the Application Engineers here at EXAIR will certainly be able to help!

I recently received an e-mail from a gentleman who was suffering from that very problem. They had a Vortex Tube installed in a camera cooling application near a boiler.  The engineer who designed the project was no longer with the company, and they could not determine a Model number or when they had purchased it. They saw the EXAIR sticker, along with our contact information, and reached out for help.

The Vortex Tubes come in different sizes based on the available compressed air supply as well as the level of refrigeration needed. We have Vortex Tubes for max refrigeration that contain our “R” style generators, as well as Vortex Tubes for a maximum cold temperature (cryogenic applications) that contain our “C” style generators. In addition to our standard Vortex Tubes, we also offer models for High Temperature applications. In order to identify the style, you must remove the muffler or cold cap to access the generator installed inside. All standard Vortex Tubes will have a white plastic generator, all High Temperature models will have a brass generator installed inside. While we do include a small circular label that indicates the required SCFM at 100 PSIG, we still must know if it’s a maximum cold temperature or maximum refrigeration style of tube.

Included on the generator there will be a stamp that indicates the cooling capacity and air consumption of the tube. In this case, a plastic generator was found inside stamped with “30-R”. This tells us that it’s a Model 3230.

If you’re considering expanding a current line into other parts of your facility, or perhaps expanding to a new location and need help identifying your EXAIR products; give an Application Engineer a call and we’ll be sure you get the right products on order!

Tyler Daniel, CCASS

Application Engineer

Twitter: @EXAIR_TD

E-mail: tylerdaniel@exair.com

HOT OFF THE PRESS: EXAIR’s New Catalog 34 In-House!

At EXAIR, continuous improvement is a way of life. We pride ourselves in consistently offering a wide variety of solutions and continuously looking at ways to improve on existing product lines and expand new ones. It’s something that sets us apart from other manufacturers.

This year, EXAIR released the 34th edition of the catalog (click here to request one!). As is always the case, it’s filled with detailed information on each of our product lines. Technical specifications, product dimensions, application examples, just about everything you’ll need to determine which solution is best for you.

For this year we’ve added (3) new products that you’ll find in this edition. First is an expansion of EXAIR’s Liquid Atomizing Spray Nozzles: The 3/8 NPT HollowStream Cone Nozzle. With a single 3/8 NPT liquid connection, this nozzle offers a liquid flow rate of up to 7.28 GPM at 60 PSI liquid pressure in a hollow shaped cone pattern.

We also added to our Intellistat® Static Eliminators Product Line with the new Intellistat® Ion Air Nozzle. Similar to our Intellistat® Ion Air Gun, the Model 8505 offers the same +/- 30V offset without the need to operate the manual trigger. This new nozzle is ideal for applications that require a solution that can be benchtop mounted, providing hands-free operation and static neutralization. It’s designed with the same convenient features in the Intellistat® Ion Air Gun with the simple 6mm push-in air connection and LED lights to indicate functionality. Each comes with a compact stainless steel mounting bracket pre-mounted for quick and easy installation right out of the box.

Finally, we introduced an entirely new line of Safety Air Guns: The TurboBlast Safety Air Gun. Using EXAIR’s largest Super Air Nozzles, the TurboBlast Safety Air Gun delivers the most powerful force of any gun with a comfortable easy-to-use handle. Models are available with an adjustable gate valve that allows for easy adjustments to the air consumption and force with a simple turn of the adjustment valve. All models are available with or without the gate valve and with 1′ (included on base models), 3′, or 6′ extensions. They also come with an installed nozzle guard to protect the nozzle fins from damage should the gun ever be dropped by operators.

Look no further than EXAIR when it comes to innovative compressed air solutions. Give us a call to discuss any of our new (and existing!) product lines and learn how we can help improve your processes.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

Turn Ordinary Pipe Into A Powerful Transfer System w/ EXAIR’s Threaded Line Vac!

EXAIR’s Line Vacs are the ideal low-cost solution for bulk material transfer or trim and scrap removal. Available with NPT threaded connections, EXAIR’s Threaded Line Vacs allow you to convert ordinary pipe into a powerful conveying system for parts, scrap, trim, and other bulk materials. With performance identical to that of the Standard Line Vac, the Threaded Line Vac is available in sizes ranging from as small as 3/8 NPT and up to 3” NPT. There’s a suitable Line Vac for most standard sized NPT pipe common in any industrial facility.

The Threaded Line Vac is available in a range of different materials: Aluminum, Type 303 Stainless Steel, Type 316 Stainless Steel, and as a Heavy Duty conveyor constructed of a hardened alloy steel for use in abrasive applications. Where most materials or hard anodized coatings wear out or wear off over time, the Heavy Duty Line Vac is the ideal solution for heavy and abrasive materials. In addition to being abrasive resistant, the Heavy Duty Line Vac is also more powerful and suitable for longer vertical and horizontal transfer distances.

Each style of Threaded Line Vac is also available as a High Temperature option. By replacing the traditional o-rings with graphite seals, we’re able to provide a solution capable of withstanding temperatures up to 900°F!!!

The conveyance rate through the Line Vac is infinitely adjustable by regulating the air pressure supplied to it. At lower pressures, the conveyance rate (and air consumption) will decrease. At higher pressures, the conveyance rate will increase. If you have a Threaded Line Vac with the standard performance but need just a little bit more, the option also exists for a High Power unit that would match the performance of the similarly sized Heavy Duty. This can be ordered from the factory with an “HP” prefix, or modified yourself. Check out our video to see just how simple it is to get more out of your Threaded Line Vac.

With all sizes and materials on the shelf and in stock, we’re able to get a solution out to you quickly. We’ll ship out the very same day for stock orders received by 2:00 ET. Backed by our Unconditional 30 Day Guarantee, you’re able to make sure it is the right solution for you before committing to keep it. If you have an application that could be better served with an in-line pneumatic conveyor, give us a call. We’ll be happy to help you determine the most suitable size for the application.

Tyler Daniel, CCASS

Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD