Replacing a Drilled Pipe for a Rubber Sheet Manufacturer

Published on by John BallLeave a comment

We received a call about an application to remove water from the surface of rubber sheets.  The reason for the call was because they were using a drilled pipe. It was loud and not removing an adequate amount of water.  (Reference the photo below).  EXAIR comes across this quite a bit.  A drilled pipe has turbulent flow which causes loud noises, ineffective blowing, and wastes compressed air.  With our Super Air Knives, we can create a stronger force as the airstream is laminar.  With the laminar flow, they are also quiet.  For example, our Super Air Knives have a noise level of only 71 dBA at 80 PSIG.  Also, since all of the air volume is traveling in the same direction, the liquid water will flow away from the airstream. 

The rubber sheet was 1200 mm wide, and I recommended a model 110248 48” (1,219 mm) Aluminum Super Air Knife Kit.  The kit includes the Super Air Knife, a filter, a regulator, and a shim set.  The filter removes the debris and water from the compressed air line to optimize the performance of the air knife as well as keep your product clean.  The regulator is used to make the “fine” adjustment to the blowing force while the shim set is used as the “coarse” adjustment.  Now they could reduce the inlet pressure to not overuse the compressed air and to get the proper removal of water from the sheet.  And with the 40:1 amplification ratio, the Super Air Knife will bring in 40 parts of ambient air to every part of compressed air, saving them a lot of money. 

After installation, the customer contacted me again and mentioned that they thought the performance would be better.  They sent me a photo of the setup.  (Reference below).  I noticed that they mounted the Super Air Knife as they did with the drilled pipe.  They had the Super Air Knife blowing perpendicular to the surface, which is not optimal.  I sent them the following setup points to help. 

Contact time is effectively the space in which the target is located within the airstream.  The longer the contact time, the more effective the Air Knife is at removing contamination (water in this case).   When customers install EXAIR Super Air Knives, they can have a tendency to install them incorrectly, reducing their performance capability.  In the photo above, you can see that the Super Air Knife is at 90 degrees to the surface of target travel, reducing contact time to a minimal value.  The following suggestions are how we would advise customers to mount our equipment to get the most effectiveness within their operation.

  1. Angle – EXAIR machines a chamfer on the cap of the Super Air Knife as a starting point.  You want to have the chamfer parallel with the target line.  This will create an air flow angle at about 45 degrees.  This angle will increase the contact area and contact time, which is very beneficial for removing debris and/or heat. (Note: this would indicate that the cap is mounted nearest to the surface being treated. 
  2. Distance — For optimum performance, the Air Knife should be between 3” (76mm) to 12” (305mm) from the target.  If the Super Air Knife is too close, the amplification ratio cannot propagate and the force is reduced.  If you are too far from the target surface, the air pattern will start to change, causing the velocity and force to decrease, resulting in less effective blowing action. 
  3. Counter-Flow — The direction of the air flow should be blowing against the target surface movement, in what we term a counter-flow direction.  Example: if the target parts are moving from left to right on a conveyor, you want the Air Knife to blow from right to left.  This will allow the contamination to be blown back away from the cleaned surfaces into the direction it came from, and it will increase the impact force to remove contamination, i.e. a head-on collision vs. a rear-end collision.

With these few simple steps, this customer was able to maximize the performance of their EXAIR Super Air Knife.  The sheets were dried through improved technology, efficiency, and correct positioning.  If you are still using antiquated products for blow-off, and you wish to improve your process with quiet, safe, and efficient products, an Application Engineer at EXAIR can assist you. 

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

UL Classified Explained

Published on by jasonkirbyLeave a comment

A UL Classified mark from UL Solutions signifies that a product has undergone testing for specific hazards or performance criteria under controlled conditions, rather than having completed a thorough and comprehensive safety evaluation. This classification is particularly relevant for industrial equipment, construction materials, and products designed to withstand fire, such as fire-resistant doors. It is important to understand that while a UL Classified mark indicates a level of safety and performance, it does not equate to a full UL Listing, which involves more extensive testing and evaluation processes. Therefore, products bearing the UL Classified mark should be viewed as having met certain safety standards, but users should remain aware of the limitations of this certification in terms of overall safety assurance.

Key Aspects of UL Classified Products

  • Targeted Evaluation — Targeted evaluation focuses on assessing specific characteristics, such as fire resistance, toxicity, and impact resistance, rather than adhering to comprehensive safety standards. This approach allows for a more precise understanding of a material’s performance in critical areas, ensuring that essential safety aspects are thoroughly examined.
  • Specific Usage — These products are designed for particular environments or applications, including hazardous areas, explosive settings, or specialized construction projects.
  • Distinction from Listed – Classified products differ from UL Listed products in that they are not subjected to the same rigorous safety evaluations. While UL Listed items are assessed for comprehensive safety standards, Classified products only comply with a subset of these requirements.
  • Labeling — Labeling typically features a statement that clarifies the limited scope of the evaluation, such as indicating that it is “Classified with respect to” a particular property. It is essential to adhere to the specified language when crafting responses and to consider any relevant modifiers without explicitly mentioning them.

Many of our products are UL Listed or UL Recognized; however, the Hazardous Location Cabinet Cooler Systems undergo additional evaluation to confirm their safety when utilized correctly in classified environments. UL Classified provides various levels of certification. These cooler systems are specifically engineered for use with purged and pressurized systems in designated hazardous locations.

Class I Div 1, Groups A, B, C, and D
Class II Div 1, Groups E, F, and G
Class III

If you have questions about our UL classification, or anything regarding EXAIR and our products, please do not hesitate to reach out.

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

Compressed Air Is Powering the Energy Transition — Not Just Manufacturing

Published on by Jordan T ShouseLeave a comment

A major breakthrough just hit the industry: researchers unveiled the world’s most powerful single-unit compressed air energy storage (CAES) compressor, rated at 101 MW.

  • Achieves ~88% efficiency at max discharge pressure
  • More than doubles the power of prior single-unit CAES compressors
  • Designed to store energy by compressing air for later electricity generation

This positions compressed air not just as a plant utility—but as a grid-scale energy storage solution.

From Shop Air to Grid Power

For decades, compressed air has been known as the “fourth utility” of manufacturing—powering tools, automation, conveying systems, and production lines across nearly every industrial sector.

But today, compressed air is stepping into a much larger role.

Recent breakthroughs in compressed air energy storage (CAES) technology are transforming compressed air from a plant-floor necessity into a grid-scale energy solution. Massive new compressor systems are now capable of storing surplus renewable energy and releasing it back into the electrical grid when demand spikes.

In other words, compressed air isn’t just powering production anymore—it’s helping power the future of energy.

What Is Compressed Air Energy Storage (CAES)?

Compressed Air Energy Storage is a method of storing energy for later use—similar in purpose to batteries, but very different in scale and operation.

Here’s how it works:

  1. Energy Capture
    Excess electricity—often from renewable sources like wind or solar—is used to power large compressors.
  2. Air Compression & Storage
    The compressed air is stored in underground caverns, tanks, or geological formations.
  3. Energy Release
    When electricity demand rises, the stored air is released, heated, and expanded through turbines to generate power.

Why CAES Matters

Renewable energy plays a critical role in the global shift toward sustainability, but it comes with a fundamental challenge: intermittency. Solar power only generates electricity during daylight hours, wind output fluctuates based on weather conditions, and grid demand changes constantly throughout the day. This mismatch between energy production and consumption creates reliability challenges for utilities. Compressed Air Energy Storage (CAES) helps solve this issue by capturing excess energy when supply is high and releasing it when demand spikes. The technology provides long-duration energy storage, supports grid stabilization, helps meet peak demand, and reduces reliance on fossil fuel peaker plants. While lithium-ion batteries currently dominate short-term storage solutions, compressed air stands out for its ability to store massive volumes of energy over longer periods—making it especially well suited for utility-scale applications.

A Breakthrough Moment for Compressed Air

Recent advancements in high-capacity compressors designed specifically for energy storage are pushing the boundaries of what compressed air technology can achieve. These next-generation systems deliver unprecedented compression power, achieve significantly higher efficiency levels, and are engineered to support renewable energy integration at grid scale. By reducing energy loss during compression and discharge cycles, they make large-scale air storage more practical and economically viable than ever before. This innovation marks a turning point for the industry: compressed air is no longer confined to manufacturing facilities—it is now being positioned as a core component of national energy infrastructure planning and the broader transition to renewable power.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email
Find us on the Web 

Schematic of the compressed air energy storage method courtesy of (Image: https://voltatechnique.com/technology/) Creative Commons License

Finding and Fixing Compressed Air Leaks

Published on by jasonkirbyLeave a comment

One of the most significant challenges facing compressed air systems is the presence of leaks. The subtle hissing sound emanating from the pipelines can lead to substantial financial losses for your company. A university study revealed that in poorly maintained systems, approximately 30% of compressor capacity is wasted due to air leaks. Unfortunately, many organizations neglect to implement leak prevention programs, resulting in inefficient systems. To quantify the impact, an inaudible leak can cost as much as $130 annually, and this is just for a single leak within extensive compressed air lines. For audible leaks, the accompanying chart illustrates the potential financial waste based on the size of the leak. Unlike hydraulic systems, compressed air leaks do not create visible messes, making them harder to detect and requiring alternative methods for identification.

Leaks commonly occur at threaded fittings, connections, hoses, and pneumatic components such as valves, regulators, and drains. EXAIR’s Optimization products are specifically designed to enhance the efficiency of your compressed air system, with leak elimination being the most effective strategy. Utilizing Ultrasonic Leak Detectors allows for the identification of air leaks, while Digital Flowmeters enable monitoring of system flow, particularly during non-production periods. By incorporating these tools into a leak prevention program, you can significantly improve your ability to detect and address leaks, ensuring your compressed air system operates at peak performance.

When a leak occurs, it produces ultrasonic sounds due to turbulence, often at frequencies above 20 kHz, which are inaudible to the human ear. The EXAIR Ultrasonic Leak Detector, model 9207, is designed to detect these frequencies and convert them into audible sounds through a technique known as “heterodyning.” This device features a signal strength indicator and a bar graph display, enabling users to identify even the smallest leaks. It includes two attachments: a parabolic microphone for locating leaks from distances of up to 20 feet, and a tube attachment for pinpointing the exact source of a leak among multiple connections within a pipe. Once identified, leaks can be marked for repair.

Digital Flowmeters enable continuous monitoring for waste, particularly in pneumatic systems where air leaks can arise unexpectedly. By isolating different sections of your system, you can conduct systematic checks and analyze flow readings with the Digital Flowmeter. Additionally, tracking results over time can provide valuable insights into system performance. We also offer a USB Datalogger option, allowing you to set specific time intervals for recording air flows. After capturing the data, you can connect the USB to your computer and utilize downloadable software to review the information, which can also be exported to an Excel spreadsheet for further analysis. If you notice a consistent upward trend in flow readings for a particular process, you can employ an Ultrasonic Leak Detector to identify the presence and location of any leaks. Furthermore, the Digital Flow Meter serves as a proactive tool, helping to indicate potential failures in your pneumatic system by analyzing trends in the readings over time.

If you have questions about finding and fixing compressed air leaks, or anything regarding EXAIR and our products, please do not hesitate to reach out.

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