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Week 6 Back to Basics- Control the Pressure

Published on by Brian FarnoLeave a comment

If you’ve been following along with this blog miniseries, you know we’ve reached the final step in the Six Steps to Optimizing Your Compressed Air System. Each step so far has built toward this moment—and today we add the last piece of the puzzle.

The final step is simple but powerful: control the air pressure at the point of use to minimize consumption.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

This is done by installing one of our pressure regulators, available in multiple pipe sizes and flow capacities. A small change in pressure makes a big impact. For example, reducing operating pressure from 100 PSIG to 80 PSIG lowers energy use by nearly 20%. In many cases, operations can run at even lower pressures, unlocking even greater savings.

This reduction in energy use is also coupled with the fact that pressure regulators make any compressed air-operated tool infinitely adjustable. Not all applications require the full output force or RPM, or conveying rate that can be achieved at full line pressure with a compressed air-operated product. And so the humble pressure regulator enables this ability for energy savings and control that is on par with any electrical control for voltage or even frequency. Pressure regulators also facilitate our working mantra to use the least amount of pressure and volume necessary to accommodate the application objectives.

All of our regulators are standard stock items, which means they can ship the same day if ordered by 2:00 P.M. Eastern Time. Plus, with 2D and 3D CAD models available through our CAD Library, you can design your entire compressed air system virtually before making a single cut in pipe.

This step, combined with the previous five, gives you a complete roadmap to compressed air optimization. From measuring usage and fixing leaks, to implementing engineered solutions, automating control, using intermediate storage, and now regulating pressure—EXAIR is here to help make the process straightforward and effective.

As always, if you’d like to discuss your application or explore how we can help you optimize your compressed air system, feel free to reach out.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR Super Air Knives and Plumbing Kits

Published on by Jordan T ShouseLeave a comment

When it comes to drying, cooling, or cleaning processes, efficiency and consistency matter. EXAIR’s Super Air Knives are engineered to deliver a uniform sheet of air across the entire length of the knife, making them the ideal choice for a wide range of industrial applications.

Sixteen stock lengths, and Four stock Materials

Why Choose EXAIR Super Air Knives?

The Super Air Knife is designed for energy efficiency, low noise, and powerful performance. By entraining surrounding air at a 40:1 ratio, it amplifies the airflow while minimizing compressed air consumption. This results in:

  • Up to 90% air savings compared to open pipe blowoffs.
  • Quiet operation, typically under 69 dBA—even at 80 PSIG.
  • Uniform airflow across the full length, ensuring even drying and debris removal.
  • Maintenance-free operation with no moving parts to wear out or require adjustment.

These air knives are available in aluminum, 303 and 316 stainless steel, and PVDF, making them suitable for everything from general industrial use to harsh chemical and washdown environments.

Streamlined Installation with Plumbing Kits

To make setup simple, EXAIR offers Plumbing Kits—pre-assembled and ready-to-install packages that include everything you need for optimal performance. Each kit includes:

  • Properly sized fittings and hoses for balanced air distribution
  • Crosses and tees for different length knives
  • Optional kits with filter and regulator assemblies to ensure clean, controlled air supply

Plumbing Kits eliminate the guesswork and ensure your Super Air Knife operates at its best from day one. They also save valuable installation time and guarantee consistent performance across multiple units.

A Complete System for Peak Performance

When combined, EXAIR’s Super Air Knives and Plumbing Kits provide a turnkey solution that delivers:

  • Consistent airflow
  • Simplified setup and maintenance
  • Lower installtion costs
  • Increased productivity and product quality

From drying bottles on a packaging line to removing debris in machining or coating operations, EXAIR’s Super Air Knife system is engineered to outperform traditional blow off methods. Ready to improve efficiency and lower energy costs? Explore EXAIR’s full line of Super Air Knives and Plumbing Kits to find the best setup for your application.

Jordan Shouse, CCASS

Application Engineer

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Week 4 Back to Basics— Shut It Down When It Isn’t Needed

Published on by Brian FarnoLeave a comment

Well, trusty blog readers, we are now two-thirds of the way through the Six Steps to Optimizing Your Compressed Air System.

So far, we’ve:

The next step is simple but powerful: turn off compressed air applications when they’re not needed.

If your process doesn’t require compressed air continuously, the EXAIR Electronic Flow Control (EFC) can help. This device uses a sensor to automatically control how long your compressed air operation runs, turning it on only when needed.

A great example is from a customer who used compressed air to clean computer monitors. When the screen wasn’t in the airstream, the air was simply wasted. With the EFC, air was shut off automatically whenever it wasn’t needed—saving energy, reducing costs, and extending the life of equipment.

The objective in this step is crystal clear: when your compressed air doesn’t need to be on, turn it off and save.

For more information on the EFC—or on any part of our Six Steps to Optimizing Your Compressed Air System—feel free to contact us.

Until next week, keep optimizing.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Week 3 Back to Basics – Replace Inefficient Blowoffs

Published on by Brian FarnoLeave a comment

In the last post of this series, we talked about finding and fixing leaks in your compressed air system. Many readers found that step especially valuable—leak detection alone can uncover major savings opportunities. Now, it’s time to move on to step three in the Six Steps to Optimizing Your Compressed Air System: implementing engineered solutions.

Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice.

This is where our Application Engineers can really help. Whether your application calls for Air Knives, Super Air Nozzles, or another one of our engineered products, we can guide you to the right solution. If you already know the consumption rates of your existing setup, we can even help you calculate the savings you’ll see by switching.

Step three is often where customers begin to notice the biggest impact. Replacing an open pipe or a non-engineered blowoff with an engineered solution can drastically reduce compressed air usage. The difference becomes obvious when your compressor cycles less frequently—or in some cases, when you’re able to shut down a secondary compressor altogether.

In the next post of this series, we’ll cover step four: an even simpler way to extend your savings by turning air off when it isn’t needed. Until then, keep working toward a more efficient compressed air system.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF