Creating an Efficient Compressed Air System

The electrical costs associated with generating compressed air make it the most expensive utility in any industrial facility. In order to help offset these costs, it’s imperative that the system is operating as efficiently as possible. I’d like to take a moment to walk you through some of the ways that you can work towards making your compressed air system more efficient.

The first step you should take is to identify and fix any leaks within the distribution piping. According to the Compressed Air Challenge, up to 30% of all compressed air generated is lost through leaks. This ends up accounting for nearly 10% of your overall energy costs!! To put leaks in perspective, take a look at the graphic below from the Best Practices for Compressed Air Systems handbook.

Compressed air leaks don’t just waste energy, but they can also contribute to other operating losses. If enough air is lost through leaks, this can also cause a drop in system pressure. This can affect the functionality of other compressed air operated equipment and processes. This pressure drop can affect the efficiency of the equipment causing it to cycle on/off more frequently or to not work properly. This can lead to anything from rejected products to increased running time. With an increase in running time, there’s also the need for more frequent maintenance and unscheduled downtime.

You can perform a compressed air audit in your facility using an EXAIR Model 9061 Ultrasonic Leak Detector. If you’d prefer someone come in and do this for you, there are several companies that offer energy audit services where this will be a focal point of the process.

Speaking of maintenance, proper compressor maintenance is also critical to the overall efficiency of the system. Like all industrial equipment, a proper maintenance schedule is required in order to ensure things are operating at peak efficiency. Inadequate compressor maintenance can have a significant impact on energy consumption via lower compressor efficiency. A regular preventative maintenance schedule is required in order to keep things in good shape. The compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, and dryer all need to be maintained. This can be done yourself or through a reputable compressor dealer. The costs associated with these services are outweighed in the improved reliability and performance of the compressor. A well-maintained system will not cause unexpected shutdowns and will also cost less to operate.

The manner in which you use your compressed air at the point of use should also be evaluated. Inefficient, homemade solutions are thought to be a cheap and quick solution. Unfortunately, the costs to supply these inefficient solutions with compressed air can quickly outweigh the costs of an engineered solution. An engineered compressed air nozzle such as EXAIR’s line of Super Air Nozzles are designed to utilize the coanda effect. Free, ambient air from the environment is entrained into the airflow along with the supplied compressed air. This maximizes the force and flow of the nozzle while keeping compressed air usage to a minimum.

Another method of making your compressed air system more efficient is actually quite simple: regulating the supply pressure. By installing pressure regulators at the point of use for each of your various point of use devices, you can reduce the consumption simply by reducing the pressure. This can’t be done for everything, but I’d be willing to bet that several tasks could be accomplished with the same level of efficiency at a reduced pressure. Most shop air runs at around 80-90 psig, but for general blowoff applications you can often get by operating at a lower pressure. Another simple, but often overlooked, method is to simply shut off the compressed air supply when not in use. If you haven’t yet performed an audit to identify compressed air leaks this is even more of a no-brainer. When operators go to lunch or during breaks, what’s stopping you from just simply turning a valve to shut off the supply of air? It seems simple and minute, but each step goes a long way towards reducing your overall air consumption and ultimately your energy costs.

Tyler Daniel, CCASS

Application Engineer
Twitter: @EXAIR_TD

Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition

What’s So Great About Compressed Air?

Compressed air is commonly known as “the fourth utility” – along with electricity, water, and gas – due to its ubiquitous use in modern industry. But…why? If you compare the power required to make it, versus the work you can get out of it, it’s abysmally inefficient. And, while it won’t electrocute you, drown you, or blow you up (like the “first three” utilities, respectively), purposely depressurizing a compressed air line comes with its own particular set of risk factors.

Of course, benefits outweigh inefficiencies and risks in many things most of us do every day. Over half of the energy released in your car’s engine goes to heat & friction, instead of turning the wheels. Insurance companies say the typical American driver has a 77% chance of getting into an automobile accident EVERY YEAR, and that most of us will be in up to THREE traffic accidents in our lifetimes. Looking at the number of fellow commuters I saw on my way to work this morning, it’s clear, though, that most of us are ready to accept that inefficiency and risk. And that’s not so surprising, considering they’re mitigated greatly by ever improving technology in fuel efficiency, and safety.

It’s, of course, the same with compressed air use, and the “first three” utilities as well: regulation, training, and engineering lower the aforementioned risks to broadly accepted levels. These disciplines also provide for the most efficient use, in spite of the inherent inefficiencies (no engine is 100% efficient) – getting the most out of what you have is “the name of the game”. So, how does all of this apply to industrial use of compressed air?


  • Regulation: In the United States, the Occupational Health & Safety Administration (OSHA) limits the nozzle pressure or or opening of a gun, pipe, cleaning lance, etc., when used for cleaning to 30psi, to protect against dead-ending such a device against your skin, which can cause a deadly condition known as an air embolism. This same directive mandates “effective chip guarding” to keep the blown off debris from hitting the operator. EXAIR Corporation has been in the business of making engineered compressed air products that comply with this directive for almost forty years now.
  • Training: There are companies whose sole purpose is to train & certify personnel in both the management, and operation, of industrial equipment in a safe manner. At EXAIR Corporation, our Safety Manager maintains certification from such an agency, which qualifies him to conduct regular training to ensure safe operation of tools, equipment, and chemicals used in the manufacture of our engineered compressed air products.
  • Engineering: In the “Hierarchy of Controls” established by the National Institute of Occupational Safety & Health (NIOSH), “Engineering Controls” is considered to be less effective than “Elimination” or “Substitution” of the hazard, but more effective than “Administrative Controls” or “Personal Protective Equipment”. THAT’S why EXAIR Corporation has been doing what we do – and why we’re so successful at it – for all this time.
For more on this, I can’t recommend my colleague Jordan Shouse’s recent blog on the subject highly enough. Go read it now…this blog will wait.


  • Regulation: Since the energy crisis of the 1970’s, the United States Department of Energy has implemented numerous initiatives directed at improving energy efficiency. If you’ve ever shopped for a home appliance, you’re likely familiar with EnergyStar ratings. They have a similar program for commercial and industrial air compressors. While they’re not a government body with powers to mandate regulations, the Compressed Air Challenge membership consists of manufacturers & distributors, users, research & development agencies, energy efficiency organizations, and utilities, with key focus on providing direction for the most efficient operation of compressed air systems…from generation to point of use.
  • Training: Speaking of the Compressed Air Challenge, they, and other organizations like the Compressed Air & Gas Institute (CAGI) conduct formal training sessions, in addition to the documented direction I mentioned above. CAGI also has a personnel certification program for those interested in developing credibility and confidence by demonstrating knowledge, understanding, and expertise in the design & operation of compressed air equipment. You can even get a cool logo to put on your business cards and in your signature line.
  • Engineering: While there are multiple avenues to engineer SAFE compressed air products, not all of them are necessarily efficient as well. At EXAIR Corporation, we set ourselves above the fray by maintaining focus on safety AND efficiency. In their discussion of controls that I mentioned above, NIOSH has this to add on the subject of Engineering Controls: “The initial cost of engineering controls can be higher than the cost of administrative controls or PPE, but over the longer term, operating costs are frequently lower, and in some instances, can provide a cost savings in other areas of the process.” (emphasis mine)

To answer the question I posed in this blog’s title, there are many considerations that make compressed air great to use…among them are:

  • Pneumatic tools are lighter, cheaper, more mobile, and lower maintenance than their electrical counterparts. The risk of electrocution is also avoided.
  • Compressed air distribution systems are easier and less costly to install than electrical grids or natural gas lines.
  • Compressed air doesn’t lose energy over distance like steam.
  • Compressed air leaks, while potentially costly, don’t present an inherent safety risk to plant personnel like gas leaks or electrical “leaks” (aka electrocution hazards).

Add in safety and efficiency, and THAT’S what’s so great about compressed air. If you’d like to find out how EXAIR Corporation can help YOU get the most out of our compressed air use, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Intelligent Compressed Air: Refrigerant Dryers

When we talk with customers about their EXAIR Products, we also discuss the quality of their compressed air. Many of our products have no moving parts and are considered maintenance-free when supplied with clean, moisture free compressed air. One of the most critical aspects of a compressed air distribution system is the dryer.

No matter where you are in the world, the atmospheric air will contain water vapor. Even in the driest place in the world, McMurdo Dry Valley in Antarctica, there is some moisture in the air. As this air cools to the saturation point, also known as dew point, the vapor will condense into liquid water. The amount of this moisture will vary depending on both the ambient temperature and the relative humidity. According to the Compressed Air Challenge, a general rule of thumb is that the amount of moisture air can hold at a saturated condition will double for every increase of 20°F. In regions or periods of warmer temperatures, this poses an even greater problem. Some problems that can be associated with moisture-laden compressed air include:

  • Increased wear of moving parts due to removal of lubrication
  • Formation of rust in piping and equipment
  • Can affect the color, adherence, and finish of paint that is applied using compressed air
  • Jeopardizes processes that are dependent upon pneumatic controls. A malfunction due to rust, scale, or clogged orifices can damage product or cause costly shutdowns
  • In colder temperatures, the moisture can freeze in the control lines

In order to remove moisture from the air after compression, a dryer must be installed at the outlet of the compressor. It is recommended to dry the compressed air to a dew point at least 18°F below the lowest ambient temperature to which the distribution system or end use is exposed. A dew point of 35-38°F is often sufficient and can be achieved by a refrigerated dryer (Best Practices for Compressed Air Systems). This makes the refrigerant dryer the most commonly used type in the industry.

A refrigerant dryer works by cooling the warm air that comes out of the compressor to 35-40°F. As the temperature decreases, moisture condenses and is removed from the compressed air supply. It’s then reheated to around ambient air temperatures (this helps to prevent condensation on the outside of distribution piping) and sent out to the distribution system.

With your air clean and dry at the point of use, you’re making sure you get the most out of EXAIR’s Intelligent Compressed Air Products without adhering to pesky maintenance procedures.

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Compressor image courtesy of Tampere Hacklab via Flickr Creative Commons License

Intelligent Compressed Air: What is an Air Compressor?

One thing that is found in virtually every industrial environment is an air compressor. Some uses for the compressed air generated are: powering pneumatic tools, packaging, automation equipment, conveyors, controls systems, and various others. Pneumatic tools are favored because they tend to be smaller and more lightweight than electric tools, offer infinitely variable speed and torque, and can be safer than the hazards associated with electrical devices. In order to power these devices, compressed air must be generated.

There are two main categories of air compressors: positive-displacement and dynamic. In a positive-displacement type, a given quantity of air is trapped in a compression chamber. The volume of which it occupies is mechanically reduced (squished), causing a corresponding rise in pressure. In a dynamic compressor, velocity energy is imparted to continuously flowing air by a means of impellers rotating at a very high speed. The velocity energy is then converted into pressure energy.

Of the positive-displacement variety they are broken down further into two more categories: reciprocating and rotary. A reciprocating compressor works like a bicycle pump. A piston reduces the volume occupied by the air or gas, compressing it into a higher pressure. There are two types of reciprocating compressors, single or double-acting. Single-acting compressors are the most common and are available up to 30HP at 200 psig. Their small size and weight allow them to be installed near the point of use and avoid lengthy piping runs. These are the types of compressors that would be commonly found in your garage. The double-acting reciprocating compressor is much like its single-acting brethren, only it uses both sides of the piston and cylinder for air compression. This doubles the capacity of the compressor for a given cylinder size. They are much more efficient than single-acting compressors, but are more expensive and do require a more specialized installation and maintenance.

Rotary compressors are available in lubricant-injected or lubricant-free varieties. These types of compressors use two inter-meshing rotors that have an inlet port at one end and a discharge port at the other. Air flows through the inlet port and is trapped between the lobes and the stator. As the rotation continues, the point intermeshing begins to move along the length of the rotors. This reduces the space that is occupied by the air, resulting in an increase in pressure. In the lubricant-injected compressors, the compression chamber is lubricated between the intermeshing rotors and bearings. This takes away the heat of compression and also acts as a seal. In the lubricant-free varieties, the intermeshing rotors have very tight tolerances and are not allowed to touch. Since there is no fluid to remove the heat of compression, they typically have two stages of compression with an intercooler between and an after cooler after the second stage. Lubricant-free compressors are beneficial as they supply clean, oil-free compressed air. They are, however, more expensive and less efficient to operate than the lubricant-injected variety.

On the other side of the coin, we have the dynamic compressors. These are comprised of two main categories: axial and centrifugal. These types of compressors raise the pressure of air or gas by imparting velocity energy and converting it to pressure energy. In a centrifugal air compressor, air continuously flows and is accelerated by an impeller. This impeller can rotate at speeds that exceed 50,000 rpm. Centrifugal air compressors are generally much larger and can accommodate flow ranges of 500-100,000 CFM. They also provide lubricant-free air.

Axial compressors are used for situations that require lower pressure but high flow rates. They do not change the direction of the gas, it enters and exits the compressor in an axial direction. It is accelerated and then diffused which creates the increase in pressure. A common application that would be served by this type of compressor is to compress the air intake of gas turbines. They have a relatively high peak efficiency, however their large overall size and weight as well as the high starting power requirements pose some disadvantages.

Of course, any of these types of compressors can be used to supply air to your engineered Intelligent Compressed Air Products. If you have an application in your facility that could benefit from an engineered solution, give us a call. An Application Engineer would be happy to discuss your options with you and see to it that you’re getting the most out of your compressed air!

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Image courtesy of Compressor1 via Creative Commons License