Control Air Pressure at the Point of Use with EXAIR’s Pressure Regulators

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. To help you achieve this, EXAIR offers a line of point of use pressure regulators to make sure you’re operating at the optimal pressure for your application.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

Regulator Internal

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, using them to minimize your pressure can result in dramatic savings to your costs of compressed air.

As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down the pressure to any compressed air operated product. For example, a Model 110012 Super Air Knife will consume 42 SCFM when operated at 100 PSIG. When the pressure is reduced to 60 PSIG, this drops to just 27.6 SCFM. That’s a 34% reduction in compressed air usage, just by dialing down the pressure at the point of use!

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Industrial Housekeeping Overview: The Vac-u-Guns

Manufacturing product can be a very dirty process that can generate large amounts of biproduct, trash, and loose material that is lying around or has been spilled. Especially when it comes to spilled material you might not want get rid of the material because it is still good. Well, EXAIR has the solution for you! Introducing the Vac-U-Gun systems! The Vac-U-Gun system is just as it sounds; a hand-held vacuum cleaner that can be turned on and off by simply pulling back the trigger. This system can allow one to easily clean up messes such as metal chips, plastic pellets, nuts, bolts, paper scraps, and much more. Altogether this gives you and easy way to keep your work space clean. Best of all the Vac-U-Gun isn’t just a vacuum system it can also work as a blower to blow air or transfer material.

EXAIR’s Vac-U-Gun System

The Vac-U-Gun system works off of the same principle of Entrainment as EXAIR’s Air Amplifiers and Line Vacs which can produce a strong suction for moving material. The removable generator located in the back of the Vac-U-Gun can be easily taken out and reoriented in order to create a strong blowing force that can be used for either blowing surfaces off or transferring material.

Vac-U-Gun Kits

The Vac-U-Gun can be purchased in three different kits to help get you started:

6192 – Collection System: Vac-U-gun, reusable bag, brush, crevice tool, skimmer tool, (2) extension wands

6292 – Transfer System: Vac-U-gun, 10’ Vacuum hose, brush, crevice tool, skimmer tool, (2) extension wands

6392 – All Purpose System: Vac-U-gun, 10’ Vacuum hose, reusable bag, brush, crevice tool, skimmer tool, (2) extension wands

If you have a blind hole that you just can’t seem to be able to clean out, then look no farther than the Deep Hole Vac-U-Gun. The Deep Hole Vac-U-Gun has all the same features as the Vac-U-Gun but adds a quick blast of air to dislodge anything in the holes so it can be vacuumed up.

The air flow of EXAIR’s Deep Hole Vac-U-Gun

Currently until May 31, 2021 then take full advantage of our promo which adds a free Vac-U-Gun to the purchase of our Industrial Vacuums. Now who doesn’t like free stuff? See the link in the image below to see our promotion page. Of course, they can also be purchased separately.

Industrial Housekeeping Promo

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Efficiency Lab Leads To Big Savings

EXAIR Corporation manufactures quiet, safe, and efficient compressed air products for industry. We want our customers to get the most out of our products, and, in turn, their compressed air systems. To do that, we offer a unique service called the EXAIR Efficiency Lab. Here’s how it works:

  • An Application Engineer can arrange to have your existing compressed air device(s) sent in to our facility.
  • We’ll use our calibrated test equipment to measure the compressed air consumption, sound level, and force applied of those devices.
  • You’ll receive a detailed test report, along with our recommendations to implement an efficient, quiet, and safety compliant solution.
  • We’ll even send your tested device(s) back to you, at no charge, if you wish.

I recently had the pleasure of conducting just such a test on some air guns.  The caller was the Environmental Health & Safety Director for a plastics manufacturer.  The main concern was safety compliance…a recent audit had shown that some workstations were using handheld blowoff devices that did not comply with OSHA standard 1910.242(b), which limits dead end pressure of compressed air products used for cleaning to 30psi.

After discussing their typical uses for these (and other) air guns, they sent in a couple for testing.  Here’s what we found out:

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

The air gun with the 7″ straight extension (top) is a “textbook” example of non-compliance with OSHA standard 1910.242(b).  Because it has an open-end discharge with no relief path, this one could cause an air embolism if it were inadvertently dead-ended into the operator’s skin – a potentially fatal condition.  It also uses a considerable amount of compressed air, and is quite loud.  At 80psig supply pressure:

  • Compressed air consumption is 40.7 SCFM
  • Noise level is 95.5dBA
  • Force applied, at a distance of 12″, is 13oz

For comparison’s sake, EXAIR Model 1210-6 Soft Grip Safety Air Gun is fitted with our Super Air Nozzle, on the end of a 6″ rigid extension:

  • Compressed air consumption is 14 SCFM
  • Sound level is 74dBA
  • Force applied, at a distance of 12″, is 13oz…same as theirs.
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).

The other one is OSHA compliant (it can’t be dead-ended…the cross-drilled hole provides a relief path, but it was still pretty inefficient and loud.  At our standard test pressure of 80psig:

  • Compressed air consumption is 30.8 SCFM
  • Noise level is 94.8dBA
  • Force applied, at a distance of 12″, is 16.9oz

Although the force generated by the Model 1210 Soft Grip Safety Air Gun isn’t quite as high as theirs, it’s still our recommendation here.  Oftentimes, the flow and velocity generated by the engineered Super Air Nozzle is more than capable of meeting the needs of the typical blow off applications these types of air guns are used in.

EXAIR Efficiency Lab testing proves that replacing these air guns with our Soft Grip Safety Air Guns (or at least replacing the tips with EXAIR Super Air Nozzles…we also have adapters for that) will result in compressed air savings of 66% and 55%, respectively, and lower sound levels to within OSHA standard 1910.95(a) limits:

All EXAIR Soft Grip Safety Air Guns comply with these limits for 8 hour exposure.

If you’d like to know more about the efficiency & safety (or lack thereof) of your current air blow off devices, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Ion Air Cannon Keeps Paper Recycling Baler Working

One of the cruelest pranks I’ve ever been party to happened during my time in the United States Navy. All it took was:

  • A cigar box
  • A rubber band
  • The scrap “dots” from every 3-hole punch we could find

We cut the lid off the cigar box, filled it with the “dots,” used the lid and the rubber band to make a wind-up flapper that we stretched across the open top of the box, and carefully placed it in our Leading Petty Officer’s (LPO’s) desk drawer.  Then we waited for hilarity to ensue the next time he opened that drawer.

Unbeknownst to us, he was going to a pretty important meeting that morning, so he was wearing his Service Dress Blues (also known as “crackerjacks” – the dark wool one; not the white one on the popular snack mix box).  When he opened his desk drawer, the rubber band-powered flapper flung those little white paper dots all over him.  It was wintertime, in an office space with electric baseboard heat, so the static cling was heinous.  It took several of us with makeshift lint brushes fashioned from duct tape to get his uniform “shipshape” and presentable for the meeting.

I was reminded of this incident recently when I had the pleasure of helping a caller from a paper recycling plant, who was having a static problem in a baler, with, basically, large confetti-like pieces of shredded paper.  These shreds are pneumatically conveyed through a long 8-inch duct, where they picked up enough static to cling to the inside of the baler chute, and built up to a point where they covered the sensors that opened the chute.  This caused the chute doors to cycle without the chute being full, which triggered the baler to activate with nothing there.  The result from the operators was a lot of slamming, frustration, and cursing…which further reminded me of my LPO’s reaction to getting covered in paper dots.

While lint brushes (and duct tape, in a pinch) work just fine for removing statically charged debris from one’s clothing, the baler required a different solution…in the form of a pair of EXAIR Gen4 Ion Air Cannons.  These were installed to blow into the baler, from opposite walls just above the chute, and aimed slightly down towards the sensors.  This keeps the sensors clear until paper shred actually DOES fill the chute, allowing it to dump a whole bale’s worth of scrap, keeping the baler (and the operators) happy.

Whatever you needs, EXAIR has a Gen4 Static Eliminator product to solve your static problem.

Many industrial static charge problems have similarities to “real world” experiences that most of us are familiar with.  If you want to talk about static control, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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