Intelligent Compressed Air: Two Different Products Called “Air Amplifiers”

Published on by Russ BowmanLeave a comment
A 2psi change in compressor discharge pressure equates to a 1% change in compressor power consumption.

They say that necessity is the mother of invention, so it’s no coincidence that mechanical means of compressing air came about in the early days of the Industrial Revolution, eventually becoming known as the “4th Utility” along with electricity, water, and gas. For most of the 20th Century, compressed air system pressure was commonly generated in the neighborhood of 100psig, although many modern industrial air compressors can be operated at 160 to 200psig. Operating an air compressor at higher discharge pressure increases the cost of operation, though, so it’s in EVERYONE ‘S best interests to run compressed air systems at the lowest pressure possible, that still gets the job done for all the air-operated gear in the facility.

So, what if most of your compressed air loads operate at 80-100psig, but one (or a handful) needs 120psig? Or 160psig? Or even higher? Increasing your compressor discharge pressure from 100psig to 160psig means you’re using 30% more power to run the compressor. That’s a LOT for one (or a handful) of operations.

Good news: the laws of physics say that pressure is the amount force applied to a specific area…as in pounds(force) per square inch, or psi. So, if we apply a certain pressure to a large diameter piston, and attach that with a shaft to another smaller diameter piston, the amount of force doesn’t change, but the area does, so the pressure on the other side of the smaller piston HAS to:

Let’s say the primary pressure (P1) is 100psi, and the primary piston (D1) is 4″ in diameter, with a surface area of 12.56 in2. That means the force applied to the primary piston (D1) is : 100 lbf/in2 x 12.56 in2 = 1,256 lbf.
This is the same force applied to the air on the other side of the secondary piston (D2), which has a diameter of 2″ and a surface area of 3.14 in2. Since pressure is force divided by area, that 1,256 lbf applied to 3.14 in2 results in a secondary pressure (P2) of 400psi.

This is the basic theory behind how air (pressure) amplifiers – also known as booster regulators – work. Essentially, you’re trading compressed air flow (into the larger cylinder) for pressure. Now, if EVERYTHING you operate needs higher pressure, the best way to do that is to increase the compressor discharge pressure. But if you only have one, or a few, loads that need higher pressure, the increase in air consumption for those loads is likely less costly than compressing the air to a higher pressure than is needed for the majority of your loads.

The other type of air amplifier is the one that EXAIR manufactures – it’s an air FLOW amplifier, and here’s how it works:

In this case, we’re trading pressure for flow, and getting a much higher total developed air flow rate than just the amount of compressed air it uses. Not only does the entrained air make them incredibly efficient, it also develops a low-velocity boundary layer that attenuates the sound level of the total air flow. They can be used for cooling, drying, cleaning, ventilation, fume exhaust, and even material conveying, especially if the material to be conveyed is very light, or already airborne.

With (16) models to choose from, EXAIR Air Amplifiers are a quick and easy way to provide a tremendous amount of cooling air flow from a compact, lightweight product.

EXAIR Air Amplifiers come in a range of sizes, from 3/4″ to 8″. Super Air Amplifiers are lightweight, durable aluminum, and Adjustable Air Amplifiers are available in aluminum or 303SS. If you’d like to find out more about them, give me a call.

Russ Bowman, CCASS

Application Engineer
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April 2025 Press Release: EXAIR Sponsors University Combat Robots Team, Investing in Future Engineers

Published on by Jordan T ShouseLeave a comment

At EXAIR, we have always believed in the power of innovation, engineering, and customer service. That’s why April’s press release is about the sponsorship of the University of Cincinnati Robotics Team. The club features a team of about 10 aspiring engineers who, in between their heavy course loads, create highly technical and impressive robots that compete in different tournaments around the United States. The club itself is highly focused on building sound engineering principles and the ability to marry those principles with creativity to create a formidable machine. This sponsorship aligns with our mission to promote innovative technology and demonstrates our dedication to community support—principles that are integral to our EXAIR culture.

If you’ve never seen a Combat Robots competition, they are custom-built robots, weighing up to 250 pounds, clashing in an arena with spinning blades, flippers, and sheer mechanical might. It’s engineering meets adrenaline, and it’s the perfect playground for students to apply what they’ve learned in the classroom to real-world challenges. The university team we’re sponsoring is a group of students who design, build, and test their robots from scratch, blending mechanical engineering, electronics, and programming into a single metal crunching monster designed to eliminate their opponent. Check out the video on their Instagram below.

Sponsoring this Combat Robots team is more than just a fun project. Robotics competitions like this inspire students to pursue STEM (science, technology, engineering, and math) careers, fostering skills that are critical to industries like manufacturing, aerospace, medical, and automotive. By supporting these young engineers, we’re helping to build a pipeline of talent that will drive innovation for years to come.

This initiative also reflects our broader commitment to community engagement. Through programs like our Employee Volunteer Program, we encourage our team to contribute to causes they care about, from local charities to educational outreach. Supporting the Combat Robots team is an extension of that spirit—empowering students to dream big, take risks, and turn their ideas into reality.

We can’t wait to see what these future engineers achieve—both in the arena and beyond. Here’s to smashing robots, and building a brighter future together!

Jordan Shouse, CCASS

Application Engineer

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BattleBot Photo Courtesy of ucincy_combat_robotics

More About Compressed Air Safety

Published on by Al WooffittLeave a comment

We all know how crucial safety is in the workplace. Most companies conduct some type of annual safety training, and a key takeaway from these sessions is that safety isn’t just the job of a few individuals; it’s everyone’s responsibility. At EXAIR, we take safety very seriously. Many of our products are designed with safety as a priority, including our Safety Air Guns, which highlight our commitment to this principle. This focus is essential because using compressed air can pose health risks if not handled correctly.

In the U.S., OSHA (Occupational Safety and Health Administration) is the agency that enforces regulations to ensure safe and healthy work environments. They have the authority to impose hefty fines for any violations. When it comes to compressed air, two common violations involve air guns and blow-off devices, as outlined in 29CFR 1910.242(b) regarding dead-end pressure/chip shielding and 29CFR 1910.95(a) concerning maximum noise exposure limits.

The first regulation, 29CFR 1910.242(b), pertains to hand-held tools. It specifies that blow-off devices should not be used at pressures exceeding 30psig if the compressed air can become dead-ended. If there’s no escape route for the air, it can penetrate the skin and lead to an air embolism. A straightforward solution is to drill a hole to provide an alternate escape path, although this can introduce other safety concerns, which we’ll cover later. EXAIR’s air nozzles are designed with fins that allow air to escape safely, preventing blockage by your skin. This means you can confidently use the EXAIR Super Air Nozzles at pressures above 30psig.

The second regulation, 29CFR 1910.95(a), outlines the maximum sound levels that a person can safely be exposed to. Prolonged exposure to high sound levels can lead to permanent hearing damage. This is where the cross-drilled nozzle doesn’t quite meet the mark. While it’s safe for dead-end pressure, the noise from the turbulent airflow is quite loud. In contrast, EXAIR’s nozzles are designed to pull in surrounding air, creating a much quieter laminar flow. For instance, our Model 1210 Safety Air Gun, which features the Model 1100 Nozzle, operates at just 74dBA, well below the noise exposure limit for an 8-hour shift.

Model 1210 Soft Grip Safety Air is fitted with an EXAIR Super Air Nozzle. We can also supply it with a Rigid Extension and Chip Shield (right).

If you’re serious about compressed air safety, EXAIR’s range of safe, quiet, and efficient Safety Air Guns and Air Nozzles is an excellent option for your facility. Feel free to reach out if you want to chat about this or any other compressed air applications you might have!

Al Wooffitt
Application Engineer

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Banner image by Gerd Altmann from Pixabay

Vac-u-Gun With an Application.

Published on by John BallLeave a comment

The Vac-U-Gun is capable of both vacuuming materials and operating as a blow gun.  It has a unique design that has a reversible generator to allow modes to change simply and easily.  In this blog, I will go over the Vac-u-Gun and an application to show how versatile this product is. 

EXAIR’s Vac-U-Gun is a low-cost solution to a wide variety of smaller industrial housekeeping problems. The Vac-U-Gun is made from a durable die-cast construction and has no moving parts to replace or wear out. In addition to being easy to use, the Vac-U-Gun is also more efficient than the commonly found blow guns. By injecting a small amount of compressed air, a vacuum is then produced by a Venturi on one end and a high output flow on the other.  Switching from vacuum mode to blow-off mode can be achieved in just a matter of seconds. To change the direction of flow, simply remove the threaded cap at the end and change the orientation of the generator inside.

The Vac-U-Gun is available by itself, or as a system in one of three different kits. The model 6192 Collection System has the Vac-u-Gun, a reusable bag, a crevice tool, a brush tool, a skimmer tool, and two extension wands.  The model 6292 Transfer System has the items in model 6192 plus a 10-foot (3 meter) vacuum hose.  Model 6392 All Purpose System has all the items in both systems. 

The extension wands are 19” (48 cm) long and can be used to help to reach the floor or into tough areas.  The tools and extensions are made from plastic to help clean electrical panels safely.  The vacuum hose can reach refuse containers to collect recyclable debris.  As a blow-off tool, the Vac-u-Gun uses very little compressed air and has an amplified output of 12 times that of the compressed air usage.  So, a large volume of air can help clean quickly.

To share an application, an optical company that made lenses had 14 workstations for quality checks.  They had a model 6392 All Purpose System at each station.  Prior to the start, they would use the Vac-u-Gun to clean the surfaces.  They would do this periodically to keep the surface clean.  They also use it at the end of the workday to clean their clothes to not have any fine glass that may be attached.  The photos below show a couple of workstations.  They used the vacuum bag to capture the glass material that was being vacuumed.  The high volume of surrounding air that the Vac-u-Gun could pull, helped to clean all surfaces quickly and quietly. 

If you’re looking for a versatile gun that can help boost productivity in a number of applications within your facility, like the lens manufacturer above, look no further than the Vac-U-Gun.  In the U.S. and Canada, EXAIR offers a 30-day unconditional guarantee to try.  You can see for yourself how effective the Vac-u-Gun systems are.  If you have any questions, an Application Engineer will be able to assist you. 

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

Photo: eyeglasses-fashion-glasses-1846595.  Pixabay license.