In industrial environments, safety teams rely on the Hierarchy of Controls to reduce workplace hazards. Rather than relying on personal protective equipment (PPE), this process prioritizes eliminating risks at their source or engineering them out of the process. For manufacturers, maintenance teams, and engineers, applying the hierarchy of controls can significantly improve safety, reduce downtime, and increase efficiency.
Many compressed air applications—blow off, cooling, conveying, and static elimination—present opportunities to implement safer and more effective solutions using products from EXAIR.
What Is the Hierarchy of Controls?
The Hierarchy of Controls is a widely accepted framework in occupational safety used to minimize or eliminate exposure to hazards. It is commonly promoted by organizations like the Occupational Safety and Health Administration and the National Institute for Occupational Safety and Health.
The hierarchy ranks safety controls from most effective to least effective:
- Elimination – Remove the hazard entirely
- Substitution – Replace the hazard with a safer alternative
- Engineering Controls – Isolate people from the hazard
- Administrative Controls – Change the way people work
- Personal Protective Equipment (PPE) – Protect the worker with gear
While elimination and substitution are ideal, they are not always feasible in manufacturing environments.
Applying the Hierarchy of Controls to Compressed Air Systems
1. Elimination
The most effective control is removing the hazard entirely. In compressed air systems, this can mean eliminating unsafe blow-off methods like open pipes or drilled tubing that create excessive noise, dangerous dead-end pressure, and flying debris. Replacing these setups with engineered solutions from EXAIR Corporation removes many of these hazards while maintaining performance.
2. Substitution
Substitution replaces hazardous equipment or processes with safer alternatives. In many facilities, this involves switching from improvised blow-off devices to engineered products like air nozzles or air knives. These solutions reduce noise, improve airflow efficiency, and significantly lower compressed air consumption.
3. Engineering Controls
Engineering controls isolate workers from hazards through equipment design. Many EXAIR products function as engineering controls by improving safety and reliability in compressed air systems. Devices like safety air nozzles, cabinet coolers, and air knives help control airflow, reduce noise levels, and prevent unsafe pressure conditions.
4. Administrative Controls
Administrative controls focus on improving procedures and training. This includes compressed air safety training, pressure guidelines, and routine system audits. While helpful, these controls rely on human behavior, so they are most effective when combined with engineered solutions.
5. Personal Protective Equipment (PPE)
PPE—such as safety glasses or hearing protection—is the last line of defense. It protects workers from hazards but does not remove the risk itself. Implementing engineered compressed air solutions can reduce many hazards before PPE becomes necessary.
Compressed air is one of the most widely used utilities in manufacturing—but it’s also one of the most misused. Improper blow off setups, excessive noise, and inefficient airflow can introduce safety hazards and energy waste.
With the right approach and the right equipment, companies can create safer, quieter, and more efficient processes—while maximizing the performance of their compressed air systems.
Solutions from EXAIR, help organizations move up the hierarchy by replacing unsafe methods with engineered products designed specifically for industrial environments.
Jordan Shouse, CCASS
Application Engineer / Sales Operations Engineer
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Hierarchy of Controls Image courdsey of CDC.Gov
