Category: Compressed Air Optimization

The Smartest Way to Stop Wasting Compressed Air

Published on by Al WooffittLeave a comment

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)

Published on by Al WooffittLeave a comment

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

The Importance Of Planned Maintenance

Published on by Russ BowmanLeave a comment

“If it ain’t broke, don’t fix it” is a common phase that we’ve all heard. It’s also a recipe for disaster. Think about it:

  • Corrective maintenance is ALWAYS more expensive. An oil change in your car might set you back $50 and an hour or so, but when (not if) emulsified, contaminated oil causes your engine to seize, that’s a four (if not five) figure repair bill.
  • Corrective maintenance is also ALWAYS more inconvenient. “If you don’t schedule time for maintenance, your equipment will schedule it for you.” ’nuff said.

Anything with moving parts is going to live its best life if you maintain it properly, and your air compressor has a LOT of moving parts that are CONSTANTLY under a good deal of mechanical stress. Your compressor’s manufacturer almost certainly has a published list of recommended maintenance items, with a schedule of when they should be performed. While that list is going to vary, depending on the type of compressor you have, some of the more common items include:

  • Intake Filter: This is what removes environmental contamination from the air that the compressor is drawing in. When (not if) it gets dirty, your compressor works harder. That means higher power consumption, which means higher operating costs. It also means more heat is generated, which can wear machinery out WAY faster than it should.
  • Lubricating Oil: If your compressor is oil lubed, that oil needs to be changed periodically. The schedule for this is always going to be a certain number of hours of operation, or a certain period of time, whichever comes first. That first one is because the amount of particulate contamination is going to be roughly proportional to the amount of time the lubricated parts spend in motion. The latter is because oil just loses some of its critical lubricating properties over time.
  • Drive Equipment: The two main methods of connecting a motor to a compressor are direct drive shaft coupling, or a system of pulleys and belts. Making sure they stay aligned is critical to their operation. Depending on the nature of the drive, lubrication, tension, and physical condition are all important maintenance points as well.
  • Safety (Pressure Relief) Valve: This valve releases excess pressure if the pressure switch fails and the compressor keeps running. At the very least, this keeps your operating costs in line — the higher the discharge pressure, the higher the power consumption. And, worst case, it makes sure you don’t over pressurize the system. If your receiver tank blows up, that’s a bad day.
  • Receiver Tank Condensate Drain: While there are a number of automatic condensate drains available for industrial air compressors, many owners choose to manually drain condensate from the wet receiver. This should be done AT LEAST once a day, with some manufacturers recommending it more frequently than that. This is critical because standing water can corrode the tank from the inside over time. It can also lead to moisture carryover into the header, and it reduces the volume of available air storage in the tank.
  • Keep Clean To Keep Cool: Air compressors generate heat, both from the friction between the moving parts, and the compression itself (Gay-Lussac’s Law states that the pressure of a given mass of gas is directly proportional to its temperature as long as the volume is constant.) Some compressors are air cooled; others are water cooled. Whichever yours is, keep the heat transfer surfaces — like the fins on the air end housing (air cooled) or fins of the heat exchanger (water cooled) — clean & free of debris to maximize the heat transfer, keeping your compressor as cool as possible.

Again, these are just some of the more common maintenance items for an air compressor. If you want yours to live its best life, keep up with the manufacturer’s recommendations. Oftentimes, maintenance records are required for warranty consideration, should something fail. If you have questions about getting the most out of your compressed air system, give me a call.

Russ Bowman, CCASS

Application Engineer
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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

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