Pressure Drop vs Differential Pressure

Published on by John BallLeave a comment

I find myself interchanging these terms; pressure drop and differential pressure.  This is very common as both are determined by the change in pressure between two points.  In this blog, I will cover the difference between these two terms in my view.

Pressure drop only occurs when the air is flowing.  The higher the velocity, the higher the pressure drop.  Velocity is created when the pressure changes.  So, the higher pressure will go toward the lower pressure.  But we wish that pressure difference to be as low as possible.  Pressure drops are always a loss, and you cannot regain that energy.  Forms of pressure drop that can be found are small diameter pipes or tubing; restrictive fittings like quick disconnects, and undersized conditioning equipment like after coolers and air dryers.  If a pressure drop is too large, the pneumatic equipment will not have enough power to operate effectively and efficiently.  I have another blog with a video that helps demonstrate this, “Pressure Drop and its Relationship to Compressed Air”. 

Differential pressure can be static or flowing.  It is very similar to pressure drop except that the energy is stored.  The most common device that does this is the pressure regulator.  You can reduce the pressure downstream to the point-of-use.  This type of pressure reduction will save you money, instead of wasting money.  For every 10 PSI reduction in pressure, it will save you 5% in energy.  With blow-off devices, you want to use the least amount of pressure to “do the job”.  Over-driving compressed air pressure is a common and wasteful condition found in facilities.

Here is a graph of a typical compressed air system.  As you can see, the typical pressure drop from the air compressor to the point-of-use.  So, if you can reduce the pressure drop through the system and optimize the differential pressure from the regulator to your point-of-use, you can enhance your compressed air system.

Pressure Drop Chart

In a simple statement, pressure drop loses energy while differential pressure stores energy for later use.  EXAIR offers a variety of efficient, safe, and effective compressed air products to fit within the demand side and which can help to reduce pressure drops within a system.  This will include the EXAIR Super Air Knives, Super Air Nozzles, and Safety Air Guns.  If you wish to go further in optimizing your system, an Application Engineer at EXAIR will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Maximizing Efficiency in Material Handling: EXAIR’s Heavy Duty Line Vac and the NEW Ultra Duty Line Vac

Published on by Jordan T ShouseLeave a comment

In industries where moving abrasive materials is a daily necessity, reliable and heavy-duty equipment can make or break operational efficiency. EXAIR’s Heavy Duty Line Vac has long been a trusted solution to such challenges, and with the introduction of the Ultra Duty Line Vac, the bar has been raised even higher.

In this blog, we’ll explore the capabilities of the Heavy Duty Line Vac, and introduce the cutting-edge Ultra Duty Line Vac.

The Ultra Duty Line vac Conveying Glass Media

The Heavy Duty Line Vac is a compressed air-powered conveyor designed to tackle demanding material handling tasks. Engineered to move abrasive materials over extended vertical and horizontal distances, it outperforms standard Line Vacs with significantly boosted throughput—over 50% higher in many cases. Its hardened alloy construction resists premature wear, making it ideal for transporting materials like steel shot, garnet, metal chips, or sand, which would quickly degrade ordinary aluminum or stainless steel conveyors. Available in sizes ranging from 3/4″ to 3″, threaded or unthreaded, the Heavy Duty Line Vac seamlessly integrates with standard hoses or NPT threaded pipes, offering versatility for various applications. The Heavy Duty Line Vac is maintenance-free, with no moving parts or electrical components, ensuring safety and reliability in harsh industrial environments. Its ability to handle tough materials while maintaining low noise levels and eliminating electrical hazards makes it a go-to choice for industries ranging from manufacturing to agriculture.

2″ Heavy Duty Line Vac (left;) the new 3″ model (right.)

Building on the success of the Heavy Duty Line Vac, EXAIR introduced the Ultra Duty Line Vac this month, a game-changer for applications involving highly abrasive materials. This conveyor is optimized for wear resistance, offering unmatched durability and performance. Like its predecessor, it’s constructed from a hardened alloy, but its design is fine-tuned to handle even the most demanding jobs for extended periods by adding in a highly wear-resistant ceramic media wear plate. The Ultra Duty Line Vac moves high volumes of material with the same ease as the Heavy Duty model but with enhanced resistance to abrasion, ensuring a longer service life.

If you think a Heavy Duty or Ultra Duty might be a fit for your application, please let us know. Reach out to an Application Engineer, and we can help get you the right product.

Jordan Shouse, CCASS

Application Engineer

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Protecting Precision: Air Wipe Ensures Accurate Measurements

Published on by Tyler DanielLeave a comment

Imagine investing in a high-end laser measurement system, capable of gauging product dimensions down to fractions of a micron, only to have the readings thrown off by something as small as a speck of dust or a thin film of residue. For one of our customers, who specialize in repairing and calibrating laser gauges, this wasn’t just a “what if.” It was a real challenge that needed a reliable solution.

The answer came in the form of EXAIR’s Air Wipe.

In their setup, cylindrical products pass through a laser gauge that verifies their diameter. Any contamination on the surface risks altering the accuracy of that measurement. By installing an Air Wipe just upstream of the gauge, they created a 360° wall of compressed air that strips away residual coolant, debris, or dust. The result is a clean, consistent surface before every scan — ensuring the gauge is reading the product, not the contaminants.

Split ring design eliminates the need for product “threading” through the Air Wipe.

The beauty of the Air Wipe lies in its design. A hinged, split-body housing makes it easy to install around existing lines, while the engineered air gap creates a uniform, high-velocity sheet of air that fully encircles the product. Unlike multiple nozzles aimed at different angles, the Air Wipe eliminates guesswork and guarantees complete coverage without gaps.

This customer chose it for metrology, but the same principle applies across industries:

  • Extrusion lines use Air Wipes to remove cooling water from plastic or rubber profiles.
  • Wire and cable manufacturers rely on them to dry and clean before printing or spooling.
  • Pipe and tubing producers install them before coating or inspection processes.
  • Medical and electronics manufacturers trust them when cleanliness and precision are non-negotiable.

For this customer, the Air Wipe turned a potential weak point in their process into a strength. Instead of worrying about contaminants interfering with measurement, they can now focus on providing precise, reliable results for their clients.

It’s a simple solution that makes a big difference: when the measurement has to be right, start by making sure the surface is clean. EXAIR offers a wide variety of products that utilize a laminar flow of compressed air for cleaning, cooling, and drying operations. Give us a call today to discuss your application!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Protection Against Dead End Pressure with EXAIR Flat Super Air Nozzles

Published on by jasonkirbyLeave a comment

Safety in the workplace is of paramount importance, and most organizations recognize this by implementing annual safety training programs. A fundamental message from these sessions is that safety is a collective responsibility, not just the duty of a select few. At EXAIR, we prioritize safety in all aspects of our operations. Our commitment is evident in the design of many of our products, such as the Flat Super Air Nozzle, which emphasizes our dedication to safe practices. This focus is particularly vital, as improper handling of compressed air can lead to significant health risks.

Meets or Exceeds OSHA Requirements

In the United States, the Occupational Safety and Health Administration (OSHA) is responsible for enforcing regulations that promote safe and healthy working conditions. This agency has the power to levy significant fines for any infractions. Among the frequent violations related to compressed air are those concerning air guns and blow-off devices, specifically addressed in 29CFR 1910.242(b), which pertains to dead-end pressure and chip shielding, as well as 29CFR 1910.95(a), which sets forth the maximum permissible noise exposure levels.

The regulation 29CFR 1910.242(b) addresses the use of hand-held tools, specifically highlighting that blow-off devices must not operate at pressures exceeding 30 psig if there is a risk of compressed air becoming dead-ended. In situations where air has no escape route, it poses a serious risk of penetrating the skin and causing an air embolism. EXAIR’s air nozzles are engineered with fins that facilitate safe air release, thereby preventing skin blockage. Consequently, users can operate the EXAIR Super Air Nozzles confidently at pressures above 30 psig.

2″ Flat Super Air Nozzle

EXAIR’s Flat Super Air Nozzles distinguish themselves from other Super Air Nozzles by utilizing a design akin to an Air Knife, featuring a shim that determines the air gap instead of traditional fins for safe air release. The nozzle’s engineered lip at the outlet effectively prevents dead-ending, ensuring continuous airflow. In the event that the nozzle’s end becomes obstructed, air can still escape from the sides, maintaining safety and compliance with OSHA standards.

 If you have any questions regarding the OSHA directives mentioned above, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk