EFC – Page 2

Finding and Fixing Compressed Air Leaks

Published on February 25, 2026February 25, 2026 by jasonkirbyLeave a comment

One of the most significant challenges facing compressed air systems is the presence of leaks. The subtle hissing sound emanating from the pipelines can lead to substantial financial losses for your company. A university study revealed that in poorly maintained systems, approximately 30% of compressor capacity is wasted due to air leaks. Unfortunately, many organizations neglect to implement leak prevention programs, resulting in inefficient systems. To quantify the impact, an inaudible leak can cost as much as $130 annually, and this is just for a single leak within extensive compressed air lines. For audible leaks, the accompanying chart illustrates the potential financial waste based on the size of the leak. Unlike hydraulic systems, compressed air leaks do not create visible messes, making them harder to detect and requiring alternative methods for identification.

Leaks commonly occur at threaded fittings, connections, hoses, and pneumatic components such as valves, regulators, and drains. EXAIR’s Optimization products are specifically designed to enhance the efficiency of your compressed air system, with leak elimination being the most effective strategy. Utilizing Ultrasonic Leak Detectors allows for the identification of air leaks, while Digital Flowmeters enable monitoring of system flow, particularly during non-production periods. By incorporating these tools into a leak prevention program, you can significantly improve your ability to detect and address leaks, ensuring your compressed air system operates at peak performance.

When a leak occurs, it produces ultrasonic sounds due to turbulence, often at frequencies above 20 kHz, which are inaudible to the human ear. The EXAIR Ultrasonic Leak Detector, model 9207, is designed to detect these frequencies and convert them into audible sounds through a technique known as “heterodyning.” This device features a signal strength indicator and a bar graph display, enabling users to identify even the smallest leaks. It includes two attachments: a parabolic microphone for locating leaks from distances of up to 20 feet, and a tube attachment for pinpointing the exact source of a leak among multiple connections within a pipe. Once identified, leaks can be marked for repair.

Digital Flowmeters enable continuous monitoring for waste, particularly in pneumatic systems where air leaks can arise unexpectedly. By isolating different sections of your system, you can conduct systematic checks and analyze flow readings with the Digital Flowmeter. Additionally, tracking results over time can provide valuable insights into system performance. We also offer a USB Datalogger option, allowing you to set specific time intervals for recording air flows. After capturing the data, you can connect the USB to your computer and utilize downloadable software to review the information, which can also be exported to an Excel spreadsheet for further analysis. If you notice a consistent upward trend in flow readings for a particular process, you can employ an Ultrasonic Leak Detector to identify the presence and location of any leaks. Furthermore, the Digital Flow Meter serves as a proactive tool, helping to indicate potential failures in your pneumatic system by analyzing trends in the readings over time.

If you have questions about finding and fixing compressed air leaks, or anything regarding EXAIR and our products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

6 STEPS: [Step Four] Turn it off when not in use.

Published on January 21, 2026January 21, 2026 by Jordan T ShouseLeave a comment

Turning off compressed air when it’s not in use is one of the fastest ways to reduce energy costs, extend equipment life, and improve overall efficiency. When paired with efficient air products and proper controls, the savings can be substantial and immediate.

Compressed air is valuable. Treat it that way. Here are some helpful ways to use it when you need it!

Start by walking the plant floor and identifying applications that run continuously, especially during breaks, shift changes, or downtime. Common culprits include open blow offs, cooling air left running, or vacuum systems operating without parts present. If air is flowing without adding value, it’s costing you money. So let’s find ways to turn it off.

Tie Air Use to Production Activity
- Compressed air should only be used when production is active. Connecting air supply to machine cycles, sensors, or PLC controls ensures air flows only when parts are present or a process is occurring. Automating on/off control not only reduces waste but also improves consistency and repeatability.
Use Solenoid Valves for Automatic Shutoff
- Solenoid valves are an effective way to shut off air when equipment is idle. When integrated into machine logic or timers, they prevent air from flowing during downtime, nights, and weekends. This is especially effective for blow off and cooling applications that don’t require constant air.
Replace Open Blow offs with Efficient Nozzles
- Open pipes and tubing waste enormous amounts of compressed air. High-efficiency air nozzles and air knives are engineered to amplify airflow while consuming significantly less compressed air. Upgrading these devices not only lowers air consumption but also improves safety by reducing noise levels.
Monitor, Audit, and Reinforce
- Turning the air off once isn’t enough, it needs to become part of the culture. Regular air audits, flow monitoring, and team accountability help ensure improvements stick. Encouraging operators and maintenance teams to report unnecessary air usage creates long-term savings and reinforces best practices.

Turning compressed air off when it’s not in use is a powerful first step—but real, lasting savings come from pairing good habits with the right technology. That’s where EXAIR solutions make the difference.

EXAIR Engineered Air Nozzles replace inefficient open pipes and tubing, delivering the force you need while dramatically reducing air consumption and noise. EXAIR Air Knives provide uniform, high-velocity airflow for drying, cooling, and cleaning—using far less compressed air than homemade blow offs. When higher airflow or vacuum is required, EXAIR Air Amplifiers generate powerful output without additional energy input.

To ensure those savings are measured and maintained, EXAIR Flow Meters give you real-time visibility into compressed air usage, helping you identify waste, verify improvements, and build accountability into your process.

Compressed air doesn’t have to be a hidden cost. With smart shutdown practices and proven EXAIR products, you can turn wasted air into measurable savings—every shift, every day.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

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Back to Basics: 6 Week Recap

Published on January 19, 2026January 27, 2026 by Brian FarnoLeave a comment

When I kicked off this blog series a few weeks ago, my goal was simple: break down compressed air optimization into clear, actionable steps. Over the years, I’ve seen countless facilities struggle with the same challenges—air leaks, wasted energy, oversized compressors running nonstop—and I’ve also seen how small, deliberate changes can transform an operation.

Walking through these six steps has been a chance to not just share tools and techniques, but to reflect on the conversations I’ve had with customers who put them into practice. In some cases, it was the first time they truly measured their air use. In others, the turning point was when a simple change—like installing a regulator—let them turn off a secondary compressor altogether. Those are the moments that make optimization “click.”

Here’s a quick recap of the journey we’ve taken:

Step 1 – Measure Usage
You can’t improve what you don’t measure. Using the EXAIR Digital Flowmeter, we establish a baseline to see where the air is going and how much is being consumed.

Step 2 – Find and Fix Leaks
Leaks are like the silent thieves of a compressed air system. With the Ultrasonic Leak Detector, you can hear what your ears normally can’t and start reclaiming wasted energy.

Step 3 – Implement Engineered Solutions
Replacing open pipes and homemade blow offs with EXAIR Air Knives, Super Air Nozzles, and other engineered solutions is often where customers first see the savings—not just on the utility bill, but in quieter, safer operations.

Step 4 – Turn Air Off When Not Needed
Why run air if the process isn’t calling for it? The Electronic Flow Control (EFC) makes sure compressed air only flows when it’s truly needed.

Step 5 – Use Intermediate Storage
Like a capacitor in an electrical circuit, receiver tanks help buffer demand spikes. This keeps systems balanced and compressors from overworking.

Step 6 – Regulate Pressure at the Point of Use
Sometimes the simplest fix is the most powerful. A small reduction in pressure can equal double-digit energy savings—without affecting performance. Pressure regulators are the perfect point of use method to achieve this.

Wrapping It All Up

Looking back, these six steps aren’t just a checklist—they’re a roadmap. Each one builds momentum for the next, and together they can change how you think about compressed air entirely. For me, the most rewarding part of this series is knowing that these are the same strategies I’ve watched customers apply successfully in real-world situations.

At EXAIR, we want to make optimization practical, approachable, and sustainable. Whether you’re measuring, fixing, upgrading, or just looking for ways to cut waste, we’re here to help guide the process.

If you’d like to talk about where your system stands today, or which step might make the biggest impact for you, feel free to reach out.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

Why Engineered Air Nozzles Outperform Open Pipes (And Cut Air Use by Up to 70%)

Published on January 9, 2026January 9, 2026 by Jordan T ShouseLeave a comment

Compressed air is one of the most expensive utilities in any manufacturing facility—yet it’s often treated as “free.” One of the biggest contributors to wasted compressed air is the continued use of open pipes, drilled pipes, or homemade blowoffs for cleaning, drying, and cooling applications.

While these methods may seem simple and inexpensive, they are inefficient, unsafe, noisy, and costly over time. EXAIR Engineered Air Nozzles are designed to solve these exact problems. Often reducing compressed air consumption by up to 70% while improving performance.

Open pipes release compressed air directly to atmosphere with no control, no amplification, and no optimization. This creates several major issues:

Excessive Air Consumption

An open 1/4″ pipe at 80 PSIG can consume 25+ SCFM continuously. Multiply that across shifts, days, and multiple stations, and the cost quickly adds up.

Poor Performance

Open pipes create turbulent airflow that dissipates rapidly, requiring higher pressure and more air to achieve acceptable results.

High Noise Levels

Uncontrolled air release produces noise levels that can exceed OSHA limits, creating safety and compliance concerns.

Safety Risks

Open pipes can generate dangerous dead-end pressures and flying debris, posing serious injury risks to operators. Creating real situations where

What Makes EXAIR Engineered Air Nozzles Different?

EXAIR Engineered Air Nozzles are precision-designed to maximize force while minimizing air consumption. Instead of wasting compressed air, they use advanced airflow geometry to do more with less.

Air Amplification

EXAIR nozzles use the Coandă effect to entrain surrounding ambient air. For every unit of compressed air used, multiple units of free air are pulled into the flow—creating higher output force without increased air usage.

Optimized Flow Patterns

Rather than chaotic turbulence, engineered nozzles produce laminar, focused airflow that delivers better cleaning, drying, and cooling results at lower pressure.

Significant Air Savings

It’s common to see 30–70% reductions in air consumption when replacing open pipes with EXAIR air nozzles—often with improved performance.

Eleminate Safety Risks

Air nozzles and jets are designed to operate well above 30 PSIG while creating dead end pressures well below the OSHA limits. Giving you better performance safley.

EXAIR Model 1100 Super Air Nozzle Replaces Open Copper Pipe Blow Off

Replacing open pipes with EXAIR Engineered Air Nozzles is one of the simplest and most cost-effective improvements you can make to a compressed air system.

If you’re serious about:

Reducing energy costs
Improving safety
Lowering noise levels
Getting more from your compressed air

…it’s time to stop blowing money into the air.

EXAIR Engineered Air Nozzles prove that better design beats brute force—every time.