Tag: compressed air

The Importance Of Planned Maintenance

Published on by Russ BowmanLeave a comment

“If it ain’t broke, don’t fix it” is a common phase that we’ve all heard. It’s also a recipe for disaster. Think about it:

  • Corrective maintenance is ALWAYS more expensive. An oil change in your car might set you back $50 and an hour or so, but when (not if) emulsified, contaminated oil causes your engine to seize, that’s a four (if not five) figure repair bill.
  • Corrective maintenance is also ALWAYS more inconvenient. “If you don’t schedule time for maintenance, your equipment will schedule it for you.” ’nuff said.

Anything with moving parts is going to live its best life if you maintain it properly, and your air compressor has a LOT of moving parts that are CONSTANTLY under a good deal of mechanical stress. Your compressor’s manufacturer almost certainly has a published list of recommended maintenance items, with a schedule of when they should be performed. While that list is going to vary, depending on the type of compressor you have, some of the more common items include:

  • Intake Filter: This is what removes environmental contamination from the air that the compressor is drawing in. When (not if) it gets dirty, your compressor works harder. That means higher power consumption, which means higher operating costs. It also means more heat is generated, which can wear machinery out WAY faster than it should.
  • Lubricating Oil: If your compressor is oil lubed, that oil needs to be changed periodically. The schedule for this is always going to be a certain number of hours of operation, or a certain period of time, whichever comes first. That first one is because the amount of particulate contamination is going to be roughly proportional to the amount of time the lubricated parts spend in motion. The latter is because oil just loses some of its critical lubricating properties over time.
  • Drive Equipment: The two main methods of connecting a motor to a compressor are direct drive shaft coupling, or a system of pulleys and belts. Making sure they stay aligned is critical to their operation. Depending on the nature of the drive, lubrication, tension, and physical condition are all important maintenance points as well.
  • Safety (Pressure Relief) Valve: This valve releases excess pressure if the pressure switch fails and the compressor keeps running. At the very least, this keeps your operating costs in line — the higher the discharge pressure, the higher the power consumption. And, worst case, it makes sure you don’t over pressurize the system. If your receiver tank blows up, that’s a bad day.
  • Receiver Tank Condensate Drain: While there are a number of automatic condensate drains available for industrial air compressors, many owners choose to manually drain condensate from the wet receiver. This should be done AT LEAST once a day, with some manufacturers recommending it more frequently than that. This is critical because standing water can corrode the tank from the inside over time. It can also lead to moisture carryover into the header, and it reduces the volume of available air storage in the tank.
  • Keep Clean To Keep Cool: Air compressors generate heat, both from the friction between the moving parts, and the compression itself (Gay-Lussac’s Law states that the pressure of a given mass of gas is directly proportional to its temperature as long as the volume is constant.) Some compressors are air cooled; others are water cooled. Whichever yours is, keep the heat transfer surfaces — like the fins on the air end housing (air cooled) or fins of the heat exchanger (water cooled) — clean & free of debris to maximize the heat transfer, keeping your compressor as cool as possible.

Again, these are just some of the more common maintenance items for an air compressor. If you want yours to live its best life, keep up with the manufacturer’s recommendations. Oftentimes, maintenance records are required for warranty consideration, should something fail. If you have questions about getting the most out of your compressed air system, give me a call.

Russ Bowman, CCASS

Application Engineer
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Double-Acting Reciprocating Air Compressors: What They Are, Where They Fit, and Why Industry Still Chooses Them

Published on by Neal RakerLeave a comment

A plain-English look at a tough, “old-school” compressor design that still earns its place in modern plants.

Compressed air is one of those behind-the-scenes utilities that keeps a lot of everyday industry moving. It powers tools, helps run automated equipment, and supports processes that need clean, controlled air. There are lots of ways to make compressed air, but one of the most common “workhorse” designs is the reciprocating compressor—think of it like a mechanical bicycle pump that runs on a motor. In this post, we will focus on a specific version: the double-acting reciprocating air compressor.

What is a double-acting reciprocating air compressor?

A reciprocating air compressor uses a piston moving back and forth inside a cylinder to squeeze air into a smaller space (that is what makes the pressure go up). The “double-acting” part means it squeezes air on both sides of the piston—so it does useful work on the forward stroke and on the return stroke.

Why it matters: you can usually get more compressed air from the same basic machine size, and the output tends to be steadier than a single-acting design.

How it works (in plain language)

  1. It pulls air in. As the piston moves, a valve opens and outside air fills the cylinder.
  2. It squeezes the air. The piston comes back, shrinking the space and raising the pressure.
  3. It pushes the air out. Once the air is at a higher pressure than the system, another valve opens and the compressed air flows out.
  4. It repeats on both sides of the piston. In a double-acting design, one side is working while the other side is also taking a turn—so more of the motion becomes useful compression.

When a site needs higher pressure, reciprocating compressors are often built in stages—basically, the air gets squeezed a little, cooled down, then squeezed again. Cooling matters because air heats up when you compress it. In real installations, the compressor is usually part of a whole “compressed air system” that can include storage (an air receiver tank), cooling, drying, and filtration depending on how clean and dry the air needs to be.

How double-acting reciprocating compressors are used

You will find double-acting reciprocating compressors in places that need dependable air, especially when pressure needs are higher, or when demand goes up and down a lot during the day. Common examples include:

  • General plant air for tools, equipment, and production support—especially when the facility wants higher pressure.
  • Controls and automation (after proper drying/filtration) where steady, reliable air helps equipment behave predictably.
  • Work that comes in bursts, for example, operations that run hard for a while, then slow down—where a reciprocating machine can be a good match.
  • Job sites and temporary setups (often smaller reciprocating units), like maintenance work or seasonal blowouts.
  • Backup duty when a facility wants a second, dependable air source ready to step in.

Why industry chooses them: the “unique factors”

  • They can manage higher pressures. If the job calls for “more push,” this design is often on the shortlist.
  • Double acting = more done per stroke. Because both sides of the piston compress air, you get more output from the same basic motion.
  • They are a good fit when demand is not steady. Many sites do not use the same amount of air every minute of the day. Reciprocating machines can be controlled to respond to those changes.
  • They are built to be maintained. These compressors are known for being serviceable; parts that wear can be replaced, and the machine can keep going for a long time with proper care.
  • They match well with a “complete system.” Pairing the compressor with storage tanks, dryers, and filters can make the whole air system smoother and more dependable.

Where it fits vs. rotary screw compressors

If you have ever investigated industrial compressors, you have probably seen rotary screw compressors mentioned a lot—and for good reason. They are popular for steady, all-day air demand. Double-acting reciprocating compressors tend to shine when you need higher pressure, when air demand swings up and down, or when you want a machine that is very “mechanical” and service-friendly.

Quick selection checklist (rules of thumb):

  • Pick double-acting reciprocating when you need higher pressure, your air use changes a lot, and you value a design that can be maintained and rebuilt over time.
  • Pick rotary screw when you need lots of air, continuously, and you expect long run hours at a steady load.
  • Either way, remember: the compressor is only part of the story. Storage tanks, piping leaks, dryers, and filters can make a substantial difference in performance and cost.

Bottom line

A double-acting reciprocating air compressor is a classic workhorse: it uses a piston to compress air, and it does that work on both strokes. That simple idea—getting useful compression on the way out and the way back—helps explain why this design is still common in demanding industrial settings.

Neal Raker, Application Engineering Manager

nealraker@exair.com

4 Mistakes Plants Might Be Making with Compressed Air (and How to Avoid Them)

Published on by Jordan T ShouseLeave a comment

Compressed air is one of the most versatile and expensive utilities in any plant. It powers tools, moves products, cools processes, and keeps production running smoothly. But it’s also one of the most commonly misused resources on the floor.

Small inefficiencies add up quickly, and many facilities are losing thousands of dollars a year without realizing it. The good news? Most of these issues are easy to fix once you know where to look, especially with engineered solutions from EXAIR.

Here are four of the most common mistakes plants make with compressed air, and how to avoid them.

1. Using Open Pipes Instead of Engineered Nozzles

The Mistake:
Blowing with open pipes or drilled tubes is still surprisingly common. It “kinda works,” but it’s incredibly inefficient, noisy, and unsafe.

Why It Matters:
Open pipes consume a massive amount of compressed air and can create dangerous dead-end pressure situations. They also produce high noise levels that can exceed OSHA limits.

How to Avoid It:
Switch to engineered air nozzles and knives like EXAIR’s Super Air Nozzles or the Super Air knife. These are designed to:

  • Reduce air consumption by up to 80%
  • Meet safety standards for dead-end pressure
  • Dramatically lower noise levels

The Result:
Immediate air savings, safer operation, and a quieter plant floor.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

2. Running at Higher Pressure Than Necessary

The Mistake:
Many plants run their systems at higher pressure “just in case.” It feels safer—but it’s costing you.

Why It Matters:
Every 2 PSI increase in pressure can increase energy consumption by roughly 1%. Multiply that across your entire system, and the cost adds up fast.

How to Avoid It:
Use EXAIR’s pressure regulators to optimize pressure at the point of use instead of over-pressurizing the entire system.

The Result:
Lower energy bills and better control over your applications—without sacrificing performance.

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

3. Ignoring Compressed Air Leaks

The Mistake:
Leaks are often treated as “minor” issues and left unresolved.

Why It Matters:
Leaks can waste 20–30% of your compressed air output. That’s essentially money leaking out of your system 24/7.

How to Avoid It:

  • Conduct routine leak audits using the Model 9207 Ultrasonic Leak Detector
  • Fix worn fittings, hoses, and connections
  • Use efficient components that minimize unnecessary air use

Pairing leak reduction with efficient products from EXAIR ensures you’re not just fixing losses, you’re preventing new ones.

The Result:
Reduced compressor load, lower maintenance costs, and immediate energy savings.

4. Not Optimizing Airflow for the Application

The Mistake:
Using too much air—or the wrong type of airflow—for blowing, drying, or conveying applications.

Why It Matters:
Inefficient airflow leads to higher consumption, inconsistent performance, and unnecessary wear on equipment.

How to Avoid It:
Adopt engineered air amplification products like EXAIR’s Air Knives, Air Amplifiers, and Air Wipes. These devices entrain the surrounding air to:

  • Maximize output while minimizing compressed air use
  • Provide uniform, high-performance airflow
  • Improve drying, cleaning, and conveying efficiency

The Result:
Better process performance with significantly lower air usage.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Compressed air is too valuable to waste. The difference between an optimized system and an inefficient one often comes down to a few overlooked decisions.

By avoiding these common mistakes—and implementing engineered solutions from EXAIR—plants can:

  • Cut energy costs
  • Improve safety
  • Boost productivity
  • Extend equipment life

If your facility hasn’t evaluated its compressed air usage recently, now is the time. Even small changes can deliver fast, measurable results.

Jordan Shouse
Application Engineer
E: JordanShouse@exair.com
O: (513) 671‑3322
F: (513) 671‑3363
A: 11510 Goldcoast Dr Cincinnati OH 45249
www.exair.com

Find time on my calendar by scheduling a meeting here.

How To Rebuild A Model 9067 Pressure Regulator

Published on by Russ BowmanLeave a comment

Here’s the latest in our “how to” video series: Today, we’ll demonstrate how to rebuild our 9067 Pressure Regulator. EXAIR’s Pressure Regulators enable easy selection of an operating pressure that allows the air product to operate properly without using excessive amounts of compressed air. Reducing the air pressure from 100 PSIG to 80 PSIG reduces air consumption by almost 20% and reduces required input power by 10%. Learn how to refurbish yours in this short video.

If you have any questions, give me a call.

Russ Bowman, CCASS

Application Engineer
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