How to Save Money on Compressed Air

Compressed air can be one of the more expensive utilities to use in a facility, but a compressed air system is full of simple opportunities to increase efficiency and minimize the cost. Much like how you can take multiple steps to save electricity at your house there a few simple steps you can take to save your compressed air. These steps include finding and repairing leaks, compressor maintenance, minimizing pressure at the point of use, and turning the compressed air off when not in use. Implementing these steps and using the right tools to achieve them can lead to significant dollar savings – in fact our website case studies, other blog articles and catalog are filled with example after example of air (and dollar) savings success! And let’s be honest here, who doesn’t like saving money.

First off is finding your leaks. Leaks are one of the major wastes of compressed air in a system that could happen. Leaks in a compressed air system can account for wasting 20-30% of a compressors output. These leaks can commonly be found in pipe joints, devices that use the compressed air, quick connect fittings, and storage tanks. All of this compounds to wasting air much like a leaky faucet wastes water – little by little it grows until it simply needs to be addressed. One of the ways to help find leaks in your system is EXAIR’s affordable Ultrasonic Leak Detector. This leak detector uses ultrasonic waves to detect where costly leaks can be found so that they can be patched or fixed.

EXAIR Ultrasonic Leak Detector

Choose efficient end-use products. Engineered air knives, air amplifiers, air nozzles and safety air guns can dramatically outperform (use less air) than commercial air nozzles and in-house solutions such as drilled pipes, open air lines and other creative “fixes”. We have seen some very nice in-house solutions from customers who have put in some significant time and effort, but they all have one thing in common – they use more air than any of EXAIR’s engineered solutions.

Minimizing your pressure can also save you money by limiting the amount of compressed air that is being used. Pressure and volume go hand and hand, the higher the pressure the higher the volume of air and vice versa. By minimizing the pressure that you are using you are also minimizing the amount of air that is being used which means savings. Each CFM used can be associated with a certain price value so the less you use the more you save. You also cut down on the amount of work the compressor has to do and how often the compressor has to cycle. Pressure can be minimized using one of EXAIR’s Pressure Regulators to cut down on the amount of air being used.

EXAIR’s Pressure Regulators come in 4 different sizes

Turn off the compressed air when it is not in use. Just like how you wouldn’t leave the faucet running or lights on in a room that is not being used, don’t leave your compressed air running (insert bad dad joke). Constantly using compressed air even when not in use will cause the compressor to cycle more often wasting money. Each CFM has a price to it so don’t waste CFM’s blowing it back into the air and doing nothing. This can simply be done by adding one of EXAIR’s ball valve or solenoid valves to turn off when you are done using it. Also, if you want to take it another step farther you can look at using one of EXAIR’s Electronic Flow Controllers (EFC). The EFC uses a photo eye attached to a timer that will open a solenoid valve for a set amount of time when it detects an object within 3’ of the photo eye. This will turn the air on only when your product is in the air path and turn it off during any spaces in between.

EXAIR’s EFC in use

Compressor maintenance is another important step to minimizing the cost of compressed air. Neglected air compressors can cause a lot of issues ranging from expensive repairs to a decreases in efficiency. Wear and tear placed on the motor of an air compressor can cause the compressor to produce less compressed air (SCFM) at the same power consumption. This means you are paying the same amount of money and getting less out of it. Making sure that your compressor or any machine is always running at its optimal performance and should always be a priority for any facility.

There are many different ways to save on compressed air, these are just a few of them. Reducing air use will save money and reduce the demand on your compressor which in turn can prolong the life of your air compressor. If you have questions about how to save on compressed air or any of our engineered Intelligent Compressed Air® Products, feel free to contact EXAIR or any Application Engineer.

Cody Biehle
Application Engineer
EXAIR Corporation
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Let Solenoid Valves and Ball Valves save you Money!

Step 4 of the Six Steps to Optimizing your compressed air is to turn off your compressed air when it is not in use. This step can be done using two simple methods either by using manual controls such as ball valves or automated controllers such as solenoid valves. Manual controls are designed for long use and when switching on and off are infrequent. Ball Valves are one of the most commonly used manual shut offs for compressed air and other fluids.

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT foot valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.
Top Left: Solenoid Valve , Bottom: Manual Foot Valve , Right: Manual ball valve

By turning off your compressed air, whether it be with manual or automated controllers, a company can minimize wasted compressed air and extend the longevity of the air compressor that is used to supply the plants air. The longevity of the air compressor is increased due to reduced run time since it does not need to keep up with the constant use of compressed air. Other benefits include less use of compressed air and recouped cost of compressed air. 

EXAIR’s Ball Valves sizes 1/4″ NPT to 1-1/4″ NPT

If you have any questions on how these easy to install accessories can help save you money give us a call! One of our application engineers will be happy to assist!

Jordan Shouse
Application Engineer

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Optimize Your Intelligent Compressed Air® Products with EXAIR’s Accessories

EXAIR offers a wide variety of various accessories that can help you to better control and fine-tune any of your compressed air operated products. Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.

EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Particulate filters remove any suspended solids from the airstream, ensuring the tight orifices in the products remain free of debris. If your system has residual oil, this should also be removed with a coalescing filter. Check out this short video from my colleague, Brian Farno, that demonstrates these filters in action:

Controlling your compressed air pressure at the point of use is an excellent way of minimizing your compressed air usage. 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. 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 to the pressure to any compressed air operated product.

Taking this idea of minimizing air usage one step further, you can achieve even greater savings by simply turning the air off when not needed. The most basic option for turning off the air supply is a simple manual valve. EXAIR offers a range of various sized valves to allow you to do just that.

This process can also be automated as well. If you’d like to automate the control of your blowoff, EXAIR offers solenoid valves that can tie into your existing PLC and eliminate unnecessary air usage. For those that want a solution ready to go right out of the box, EXAIR’s Electronic Flow Controller utilizes a photoelectric sensor and solenoid valve tied to a timer that allows you to shut off the air supply when a part or component is not present. This can lead to dramatic air savings in many applications where parts are traveling along a conveyor.

Once you’ve selected an engineered compressed air nozzle for your blow off application, you’ll likely need a solution to mount and position it as well. Here’s where EXAIR’s Stay Set Hoses and Magnetic Bases come into play. EXAIR’s Stay Set Hoses are available from 6”-36” in length with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend. They’re easily repositionable as well, making them an ideal solution for applications that may require frequent repositioning due to varying parts.

In addition to the Stay Set Hoses, EXAIR also has Magnetic Bases available as well. The powerful magnet permits both horizontal and vertical mounting. A manual valve is also included that will allow you to vary the force and flow. Magnetic bases are available with one or two outlets and can be combined with any of our nozzles and Stay Set Hoses to create your own customized blowoff system.

Regardless of your application, EXAIR has the products available from stock to help optimize your processes. These accessories allow you to help optimize the use of your blowoff products and ensure reliable, repeatable performance. If you’d like to discuss an application, give us a call.

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

Save Compressed Air with the EXAIR Electronic Flow Control

The best way to save compressed air is to simply turn it off when it’s not being used. This might seem pretty simple, but there may be processes in your facility where this couldn’t be achieved by just turning a valve. In applications where product is traveling along a conveyor, and must be dried, cooled, or blown off, there is likely some spacing in between the parts. It isn’t necessary to keep the blowoff running constantly if there’s periods of intermittent spacing. To help reduce the overall load on the air compressor, implementing a solution to shut the air off in between each part can have a dramatic impact. EXAIR’s Electronic Flow Control, or EFC, is designed to improve efficiency by reducing overall compressed air usage. It utilizes a photoelectric sensor that detects when the part is present. When it’s not, it triggers a solenoid valve to close and shut off the compressed air supply.

efcapp
EXAIR EFC

One way to use the Electronic Flow Control would be for Turning a Atomizing Spray nozzle on to coat your product.  For example see the photo below where you could use the EFC to sense the pants coming down the line. Then turn the air supply on to spray a bleach solution to get the weathered look you are after. Once the pants pass the EFC will turn the nozzle off, replacing a manual operation awhile saving compressed air and your liquid solution!

Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled.  You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper.  Then set the timer module so it will run for the length of time it takes to fill the hopper.  The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.

The EFC models available from stock can accommodate flows up to 350 SCFM. For applications requiring more compressed air, EFCs with dual solenoids are also available. If you have an application in one or more of your processes where intermittent compressed air use could help save you money, give us a call. We’d be happy to take a look at the application and help determine just how quickly the EFC could start paying YOU

Jordan Shouse
Application Engineer

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