Six Steps To Optimizing Your Compressed Air System – Step 1: Measure

“To measure is to know – if you cannot measure it, you cannot improve it.”
-Lord Kelvin, mathematical physicist, engineer,and pioneer in the field of thermodynamics.

This is true of most anything. If you want to lose weight, you’re going to need a good scale. If you want to improve your time in the 100 yard dash, you’re going to need a good stopwatch. And if you want to decrease compressed air consumption, you’ll need a good flowmeter. In fact, this is the first of six steps that we can use to help you optimize your compressed air system.

Six Steps To Optimizing Your Compressed Air System

There are various methods of measuring fluid flow, but the most popular for compressed air is thermal mass air flow.  This has the distinct advantage of accurate and instantaneous measurement of MASS flow rate…which is important, because measuring VOLUMETRIC flow rate would need to be corrected for pressure in order to determine the true compressed air consumption.  My colleague John Ball explains this in detail in a most excellent blog on Actual (volume) Vs. Standard (mass) Flows.

So, now we know how to measure the mass flow rate.  Now, what do we do with it?  Well, as in the weight loss and sprint time improvements mentioned earlier, you have to know what kind of shape you’re in right now to know how far you are from where you want to be.  Stepping on a scale, timing your run, or measuring your plant’s air flow right now is your “before” data, which represents Step One.  The next Five Steps are how you get to where you want to be (for compressed air optimization, that is – there may be a different amount of steps towards your fitness/athletic goals.)  So, compressed air-wise, EXAIR offers the following solutions for Step One:

Digital Flowmeter with wireless capability.  This is our latest offering, and it doesn’t get any simpler than this.  Imagine having a flowmeter installed in your compressed air system, and having its readings continually supplied to your computer.  You can record, analyze, manipulate, and share the data with ease.

Monitor your compressed air flow wirelessly over a ZigBee mesh network.

Digital Flowmeter with USB Data Logger.  We’ve been offering these, with great success, for almost seven years now.  The Data Logger plugs into the Digital Flowmeter and, depending on how you set it up, records the flow rate from once a second (for about nine hours of data) up to once every 12 hours (for over two years worth.)  Pull it from your Digital Flowmeter whenever you want to download the data to your computer, where you can view & save it in the software we supply, or export it directly into Microsoft Excel.

From the Digital Flowmeter, to your computer, to your screen, the USB Data Logger shows how much air you’re using…and when you’re using it!

Summing Remote Display.  This connects directly to the Digital Flowmeter and can be installed up to 50 feet away.  At the push of a button, you can change the reading from actual current air consumption to usage for the last 24 hours, or total cumulative usage.  It’s powered directly from the Digital Flowmeter, so you don’t even need an electrical outlet nearby.

Monitor compressed air consumption from a convenient location, as well as last 24 hours usage and cumulative usage.

Digital Flowmeter.  As a stand-alone product, it’ll show you actual current air consumption, and the display can also be manipulated to show daily or cumulative usage. It has milliamp & pulse outputs, as well as a Serial Communication option, if you can work with any of those to get your data where you want it.

With any of the above options, or stand-alone, EXAIR’s Digital Flowmeter is your best option for Step One to optimize your compressed air system.

Stay tuned for more information on the other five steps.  If you just can’t wait, though, you can always give me a call.  I can talk about compressed air efficiency all day long, and sometimes, I do!


Digital Sound Level Meter Identifies Harmful Noise in the Workplace

slm-newlabel EXAIR offers the model 9104 Digital Sound Level Meter.  It is an easy to use instrument for measuring and monitoring the sound level pressures in and around equipment and other manufacturing processes.

Sound meters convert the movement of a thin membrane due to the pressure waves of sound into an electric signal that is processed and turned into a readable output, typically in dBA.  The dBA scale is the weighted scale that most closely matches the human ear in terms of the sounds and frequencies that can be detected.


To protect workers in the workplace from suffering hearing loss OSHA has set limits to the time of exposure based on the sound level.  The information in the OSHA Standard 29 CFR – 1910.95(a) is summarized below.

OSHA Noise Level

The Digital Sound Meter can be used to monitor and measure sound levels of manufacturing processed such as blowoffs for cooling or drying.  Many blowoffs, especially open or drilled pipes are very inefficient and can be identified as a source of excessive noise, outside the OSHA exposure ranges.  Once the noise violators are identified, a review can be done and the implementation of engineered solutions such as Super air Nozzles or Super Air Knives can be investigated. Keeping harmful noise levels in check benefits everyone involved.

The EXAIR Digital Sound Level Meter is an accurate and responsive instrument that measures the decibel level of the sound and displays the result on the large optionally back-lit LCD display. There is an “F/S” option to provide measurement in either ‘slow’ or ‘fast’ modes for stable or quickly varying noises. The ‘Max Hold’ function will capture and hold the maximum sound level, and update if a louder sound occurs.

Certification of accuracy and calibration traceable to NIST (National Institute of Standards and Technology) is included.

There is an informative Video Blog, presented by @EXAIR_LE that can be found here.

If you have questions about the Digital Sound Level Meter, or would like to talk about any of the quiet EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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FREE EXAIR Webinar – November 2nd, 2017 @ 2:00 PM EDT

On November 2, 2017 at 2 PM EDT, EXAIR Corporation will be hosting a FREE webinar titled “Optimizing Your Compressed Air System In 6 Simple Steps”.

During this short presentation, we will explain the average cost of compressed air and why it’s important to evaluate the current system. Compressed air can be expensive to produce and in many cases the compressor is the largest energy user in a plant, accounting for up to 1/3 of the total energy operating costs. In industrial settings, compressed air is often referred to as a “fourth utility” next to water, gas and electric.

Next we will show how artificial demand, through operating pressure and leaks, can account for roughly 30% of the air being lost in a system, negatively affecting a company’s bottom line. We will provide examples on how to estimate the amount of leakage in a system and ways to track the demand from point-of-use devices, to help identify areas where improvements can be made.

To close, we will demonstrate how following six simple steps can save you money by reducing compressed air use, increasing safety and making your process more efficient.


Justin Nicholl
Application Engineer

The Cost of Compressed Air Leaks Create the Need to Find and Fix

Leaks can cost you

As margins get tighter and cost of manufacturing climbs, industries are looking into other areas to be more economical.  A big focus today is in the compressed air systems.  Compressed air is considered to be the “forth” utility behind gas, water, and electricity.  It is a necessary system to run pneumatic systems, but it is the least efficient of the utilities.  For every $1.00 that is put into making compressed air, you only get roughly 5¢ of work from it.  So, it is very important to use this utility as efficiently as possible.

One of the largest problems affecting compressed air systems is leaks.  That quiet little hissing sound coming from the pipe lines is costing the company much money.  A university study was conducted to find the percentage of air leaks in a typical manufacturing plant.  In a poorly maintained system, they found on average that 30% of the compressor capacity is lost through air leaks.  In relation to the amount of electricity required to make compressed air, for every ten power plants producing electricity, there is one power plant producing electricity just for air leaks.  A majority of companies do not have a leak prevention program; so, many of these companies have poorly maintained systems. This creates a large amount of waste caused by simple air leaks.  To put a dollar value on it, a leak that you cannot physically hear can cost you as much as $130/year.  That is just for one inaudible leak in hundreds of feet of compressed air lines.  For the leaks that you can hear, you can tell by the chart below the amount of money that can be wasted by the size of the hole.  Unlike a hydraulic system, compressed air will not leave a tell-tale sign of a leak. You have to locate them by some other means.

**Note 1

Most leaks occur where you have threaded fittings, connections, hoses, and pneumatic components like valves, regulators, and drains.  The Optimization products from EXAIR are designed to help optimize your complete compressed air system.  The most effective way is to find and eliminate air leaks, and EXAIR has two products that can help do this.  The Ultrasonic Leak Detectors can find the air leaks, and the Digital Flowmeters can monitor your system for air leaks.  With both of these products included in a leak prevention program, you will be able to keep your compressed air system running optimally and reduce the wasted cost in air leaks and overusing the air compressor.

EXAIR Ultrasonic Leak Detector:

When a leak occurs, it emits an ultrasonic noise caused by turbulence.  These ultrasonic noises can be at a frequency above that which is audible for human hearing.  The EXAIR Ultrasonic Leak Detector can pick up these frequencies and make the leaks audible.  With three sensitivity ranges and LED display, you can find very minute leaks in your compressed air system.  It comes with two attachments; the parabola to locate leaks up to 20 feet away, and the tube attachment to define the exact location in the pipe line.  Once you find a leak, it can be marked for fixing.

EXAIR’s Digital Flowmeter w/ USB Data Logger

EXAIR Digital Flowmeter:

With the Digital Flowmeters, you can continuously monitor for waste.  Air leaks can occur at any time within any section of your pneumatic area.  You can do systematic checks by isolating sections with the Digital Flowmeter and watching for a flow reading.  Another way to monitor your system would be to compare the results over time.  With the Digital Flowmeters, we have a couple of options for recording the air flow data.  We have the USB Datalogger for setting certain time increments to record the air flows.  Once the information is recorded, you can connect the USB to your computer, and with the downloadable software, you can view the information and export it into an Excel spread sheet.  We also offer a wireless capability option with the Digital Flowmeters.  You can have multiple flow meters communicating through a gateway to monitor and record the flow information onto your computer system.  If you find that the flow starts trending upward for the same process, then you know that you have a leak.  It can also give you a preventive measure if your pneumatic system is starting to fail.

Compressed air leaks will rob you in performance, compressor life, and electrical cost.  It is important to have a leak prevention program to check for leaks periodically as they can happen at any time.  The EXAIR Ultrasonic Leak Detector and the Digital Flowmeters will help you accomplish this and optimize your compressed air system.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products and save yourself even more money.

John Ball
Application Engineer
Twitter: @EXAIR_jb


**Note 1: Chart was published by Compressed Air Challenge in April 1998 – Rev. 0

Calibration – Keep Your Meters True

EXAIR offers meters to measure the level of physical parameters such as sound and static. Each meter has sensitive electrical circuitry and a periodic calibration is recommended to ensure the meter readings are tried and true.

The model 9104 Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The sound meter comes from the factory with an NIST (National Institute of Standards and Technology) certificate of accuracy and calibration.  As a good practice, EXAIR recommends a yearly calibration of the instrument, and we offer a service that calibrates the unit to the same NIST standards and provide a written report of the calibration.

The model 7905 Static Meter allows easy one-hand static measurements.  It is useful in both locating sources of high static charge and checking the reduction of static after treatment with an EXAIR Static Elimination product.  The unit is sensitive and responsive, and indicates the the surface polarity of objects up to +/- 20 kV when measured from 1″ away.

It is also recommended that the Static Meter be calibrated on a yearly basis.  EXAIR offers (3) levels of calibration service.  The first two provide calibration in accordance with MIL Standards using accepted procedures and standards traceable to NIST.  The third calibration service conforms to the same Mil Standard, as well as ISO/IEC standards.

Annual calibration service of your EXAIR Digital Sound and Static Meter, along with proper care and storage, will keep your meter performing tried and true for many years, providing accurate and useful measurements.

To initiate a calibration service, give us a call and an Application Engineer will issue an Returned Good number, and provide instructions on how to ship the meter to EXAIR.

If you have questions regarding calibration services for your meters or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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OSHA 29 CFR 1910.95 – Standard on Occupational Noise Exposure

Last week, the EXAIR Blog featured an article about the OSHA Standard 1910.242(b) – Reduction of Air Pressure below 30 psi for Cleaning Purposes.  This week, we will review another OSHA standard that affects many of you in manufacturing and other industries.

OSHA 29 CFR 1910.95 – Standard on Occupational Noise Exposure discusses the effects of noise and sets limits for exposure.  Occupational noise can cause hearing loss, and also interfere with concentration and communication, disrupting the job performance. Below is a summary from the standard of the Permissible Noise Exposure (OSHA Table G-16)

OSHA Noise Level

From the chart, the time an employee can be exposed to loud noise is greatly reduced as the sound level goes up.   The use of hearing protection is helpful but relies on the operator to use consistently and correctly.  Ear plugs or ear muffs can be uncomfortable and hot, leading to possible reduced usage.  OSHA can come on site, and if violations to the sound level exposure limits are found, they can impose fines and mandate corrective action be taken place.

The recommended course of action when an operator is subjected to sound exceeding those in the chart above is to enable feasible administrative or engineering controls. Engineering controls is the arena in which EXAIR can be a great resource.

The first step in understanding and addressing any sound level issues is to measure the sound. The easy to use Digital Sound Meter, model 9104 shown below, allows for accurate testing of noise levels throughout the facility.  Noisy areas can be quickly identified, leading to review, design and implementation of the engineering controls.


Some of the worst offenders for noise violations is compressed air usage.  A prime example would be inefficient blowoffs, used for cooling, drying, or cleaning.  Open pipe, copper tube or drilled pipe are a few of the common culprits.  Not only do they consume excessive amounts of compressed air, they can produce noise levels above 100 dBA.

EXAIR manufactures a wide variety of engineered products that utilize compressed air and deliver it in a controlled manner.  This allows for the most efficient use of compressed air and keeps the sound levels much lower than the inefficient methods.  A Super Air Knife can replace a drilled pipe, reducing sound by as much as 20 dBA, while using 50-70% less compressed air.  An engineered Super Air Nozzle can replace an open pipe or copper tube and reduce sound levels down to 74 dBA, and even down to 58 dBA for the smallest available nozzles.

EXAIR has been providing Intelligent Compressed Air Products since 1983.

If you have questions regarding noise limits and how to solve any issue with an EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB


How Do I Estimate The Cost Of My Compressed Air?

Saving Money and Compressed Air

One of the best features of EXAIR products is the engineering behind the designs.  For example, our nozzles are designed to generate a maximum force possible per CFM of compressed air.  This means that the compressed air consumed by the device is at its maximum possible efficiency, which in turn reduces the compressed air demand in an application, reducing the cost of the solution.

But, how do you determine the cost of a compressed air driven product?

Step 1 – Quantify flow

The first step to determine compressed air cost is to quantify the flow rate of the product.  Most pneumatic equipment will have a spec sheet which you can reference to determine air consumption, but open pipe blowoffs and drilled holes won’t provide this type of information.  In those cases, or in any case where the compressed air flow is unknown or questionable, a compressed air flow meter can be used.  (We have Digital Flowmeters for use on compressed air piping, with or without data logging capability, and with serial or wireless communication.)

Step 2 – Calculate flow over time

Once the flow rate is known, it’s time to determine flow rates per day/week/month/year.  To do so, we will perform a bit of short and easy math.  What we will do, is use the known flow rate of the device, and multiply this by the total time in operation to determine daily, weekly, monthly, and annual usage rates.  For example:

A 1/8” open pipe blowoff will consume 70 SCFM.  In an 8 hour shift there are 480 minutes, resulting in a total consumption of 33,600 SCFM per 8 hour shift.

Step 3 – Determine cost

With a quantified flow rate, we can now determine the cost.  Many facilities will know the cost of their compressed air per CFM, but for those which don’t, a cost of ($0.25/1000 standard cubic feet) can be used.  This value is then multiplied by the total compressed air consumption from above, to give a quantified dollar amount to the compressed air driven device.

Using the flow rate from above:

If (1) shift is run per day, 5 days per week and 52 weeks per year, this open pipe blowoff will have an annual cost of $2,184.00.

Step 4 – Compare

At this point we know the real cost of the device.  The benefit to quantifying these flow rates, is when making a comparison to an alternative such as an engineered solution.  For example, if we were to replace the open pipe blowoff reference above with an EXAIR 1010SS 1/8” NPT nozzle, the compressed air demand would drop to 13 SCFM, yielding the following flow rates and costs:

If (1) shift is run per day, 5 days per week and 52 weeks per year, this open pipe blowoff will have an annual cost of $405.60.

Comparing these two solutions on an annual basis yields a difference of $1,778.40.  This means an air savings which correlates to $1,778.40 per year – just by replacing ONE open pipe blowoff with an engineered solution.  Replacing multiple open pipe blowoffs will yield repeat savings.

The 1010SS EXAIR Micro Air Nozzle

Determining the cost of a compressed air driven device can clarify the impact of a truly engineered solution.  If you have an interest in determining the cost of the compressed air devices in your facility, contact an EXAIR Application Engineer.  We’ll be happy to help.


Lee Evans
Application Engineer