Tag: Noise Reduction

Compressed Air Safety in Industrial Environments: Key Risks and Best Practices

Published on by Neal RakerLeave a comment

Compressed air powers tools, equipment, and cleaning processes in many facilities—but it can also cause serious injuries, damage equipment, and disrupt operations when used improperly. Here is a concise look at the main hazards and the practices that reduce risk.

Common compressed air hazards

  • High-pressure injection and flying debris: Air blasts can propel chips and dust into eyes and skin; air can also enter the body through cuts or openings and cause life-threatening injury.
  • Excessive noise: Blow-off and open pipes can exceed safe sound levels, contributing to permanent hearing loss and making communication harder.
  • Whipping hoses and failed fittings: A loose or damaged hose can detach and strike workers with significant force.
  • Contaminants in the air stream: Oil, water, and particulates can affect product quality, degrade tools, and create health risks in certain applications.

OSHA note: blow-off pressure limits

OSHA Standard 1910.242(b) requires compressed air used for cleaning to be reduced to less than 30 PSI at the nozzle when dead-ended (blocked), and to be used with effective chip guarding and appropriate PPE. Meeting this requirement is a baseline for a safe compressed air program.

Many facilities meet these standards by using engineered nozzles and safety air guns (for example, from EXAIR or similar manufacturers) that limit dead-end pressure, reduce noise, and improve blow-off efficiency.

Best practices checklist

  • Use engineered nozzles/air guns: Replace open pipes and improvised nozzles; choose designs that limit dead-end pressure and reduce noise.
  • Control debris: Use chip guards/shields and direct blow-off away from people and walkways.
  • Manage hoses: Secure connections, route hoses to prevent kinks and trip hazards, inspect routinely, and use whip checks where appropriate.
  • Wear the right PPE: Eye protection is essential; add hearing protection where noise is elevated; use gloves/protective clothing as the task requires.
  • Follow safe procedures: Never point compressed air at anyone or use it to clean clothing; depressurize lines before maintenance; train operators and post clear signage.
  • Maintain the system: Keep filters/dryers/lubricators serviced and repair leaks to improve safety and reduce energy waste.

The Bottom Line

Compressed air is essential—but it is not risk-free. When you pair OSHA-aligned pressure control with engineered tools, hose management, PPE, training, and routine maintenance, you reduce injuries, cut down time, and keep operations running safely.

Neal Raker, Application Engineering Manager
nealraker@exair.com

Reducing Pneumatic Exhaust Noise with EXAIR Mufflers

Published on by Jordan T ShouseLeave a comment

In many manufacturing facilities, compressed air systems are one of the largest contributors to workplace noise. Pneumatic cylinders, valves, vacuum generators, and cooling devices all exhaust compressed air, often creating sound levels high enough to require hearing protection. OSHA Standard 29 CFR 1910.95 outlines permissible workplace noise exposure levels, making noise reduction an important part of maintaining a safer and more comfortable work environment.

To help solve these issues, EXAIR offers several different styles of Silencing Mufflers designed for specific applications. Choosing the correct muffler can improve operator safety, reduce exhaust noise, and even help eliminate oil mist from compressed air systems.

Reclassifying Mufflers – Maximum Noise Reduction and Oil Removal

Reclassifying Mufflers are EXAIR’s most advanced muffler option. These mufflers are designed not only to reduce noise, but also to remove oil mist from exhausted compressed air. In pneumatic systems where lubricated air is used, exhausted oil mist can create slippery surfaces, contaminate products, and affect air quality.

EXAIR Reclassifying Mufflers can reduce sound levels by up to 35 dB while separating oil from the exhaust stream through a removable filter element. The collected oil drains into an integrated reservoir, helping facilities maintain cleaner and safer operations.

These mufflers are ideal for:

  • Pneumatic cylinders
  • Air valves
  • Lubricated compressed air systems
  • Applications where oil mist must be controlled

Sintered Bronze Mufflers – Simple and Cost Effective

Sintered Bronze Mufflers are a popular low-cost solution for reducing exhaust noise from pneumatic equipment. Their porous bronze construction allows compressed air to pass through with minimal back pressure, helping maintain proper equipment performance.

These mufflers are:

  • Easy to install
  • Available in a wide range of sizes
  • Ideal for standard cylinder and valve exhausts
  • Designed for minimal airflow restriction

Unlike Reclassifying Mufflers, Sintered Bronze Mufflers do not remove oil mist from the exhaust air. However, they remain an excellent option when a simple and economical noise reduction solution is needed.

Straight-Through Mufflers – Ideal for Remote Exhaust Applications

Straight-Through Mufflers are designed for applications where exhaust air needs to be piped away from operators or sensitive areas. These mufflers feature a corrosion-resistant aluminum shell lined with sound-absorbing foam and can reduce noise levels by up to 20 dB.

Their threaded inlet and outlet design makes them especially useful for:

  • Vortex Tubes
  • E-Vac Vacuum Generators
  • Cabinet Cooler Systems
  • Remote exhaust routing

Because the airflow passes directly through the muffler body, Straight-Through Mufflers are also less susceptible to clogging in certain applications.

Selecting the Right Muffler

Each EXAIR muffler style is designed to solve a different challenge:

Muffler TypePrimary BenefitTypical Use
Reclassifying MufflersBest noise reduction and oil removalPneumatic cylinders and lubricated systems
Sintered Bronze MufflersLow cost and easy installationGeneral pneumatic exhaust applications
Straight-Through MufflersRemote exhaust routing and lower clogging riskVacuum generators, vortex tubes, cabinet coolers

Reducing compressed air exhaust noise is often a simple upgrade that can have a major impact on workplace safety and operator comfort. Whether the goal is maximum sound reduction, oil mist filtration, or economical silencing, EXAIR offers a muffler solution designed for the application.

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.

Reducing the Noise with EXAIR Mufflers

Published on by John BallLeave a comment
Hearing loss is the best known, but not the only, ill effect of harmful noise exposure. It can also cause physical and psychological stress, impair concentration, and contribute to workplace accidents or injuries.

Many manufacturing plants have a strong focus on safety for their workers.  One major safety concern that is overlooked is noise.   The Occupational Safety and Health Administration has a directive, 29 CFR 1910.95a, that defines noise exposure levels over time.  For an eight-hour day, the maximum noise level is 90 dBA.  Hearing loss is irreversible, but it can be prevented.  The CDC, Center for Disease Control, and NIOSH, National Institute for Occupational Safety and Health, report that “approximately 18% of all manufacturing workers have hearing difficulty”1. 

EXAIR manufactures intelligent compressed air® products to reduce noise levels in the work environment with our Super Air Nozzles, Super Air Knives, and Safety Air Guns for blow-off applications.  But there is another culprit that can be heard; discharge exhaust.  In this blog, I will cover the different types of mufflers that we offer to help reduce these sound levels.

Reclassifying Mufflers are designed to have two functions. They can cut noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist, which is dangerous for operators.  Reclassifying mufflers can reduce loud noise while also collecting any contaminants in the exhaust air.

Sintered Bronze Mufflers are simple in design, cost-effective, and easy to install. They have minimal back pressure to not restrict the operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2” NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.

Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound-absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with ports of ¼” NPT, 3/8” NPT, and ¾” NPT.  One side has a female thread, while the opposite side will have a male thread.  This can allow you to connect other items like hose kits to reduce noise.

In harsh environments, Heavy Duty Mufflers are used.  They have an outer aluminum shell with an internal stainless-steel screen.  They protect components like valves and cylinders from contamination entering the part.  And, the Heavy Duty Muffler can keep contaminants like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Here is a test for you.  If you go and stand in your plant, you can probably hear loud noises coming from your pneumatic system.  EXAIR has engineered products to solve most of them.  In the Hierarchy of Controls from NIOSH, Personal Protection Equipment, or PPE, is the least effective.  A better control from this chart would be to isolate your operators from the hazard with an engineered product.  EXAIR can offer these solutions for many of your blow-off and pneumatic discharge applications.  If you wish to discuss in further details about the safety improvements that EXAIR can provide, you can contact an Application Engineer.  We will be happy to help. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Note 1: https://www.cdc.gov/niosh/topics/ohl/manufacturing.html

OSHA and Compressed Air Safety; Things to Review.

Published on by John BallLeave a comment
EXAIR Super Air Nozzles are fully OSHA Compliant – our Compliance Certificate is available upon request (left.) Your power strip and Christmas tree lights should have labels showing their current ratings – check these so you don’t overload the circuit (right.)

At EXAIR, we have a statement that says, “Safety is everyone’s responsibility.”  As a corporation, EXAIR builds its name around this by manufacturing safe and protective compressed air products.  In the United States, we have an organization called the Occupational Safety and Health Administration, OSHA, that enforces governmental directives for safe and healthy working environments.  They do training, outreach programs, and educational assistance for manufacturing plants to reduce injuries and fatalities.  They can also enforce these directives with heavy fines for violations.  With the compressed air system, the two most common violations are 29CFR 1910.242(b) for dead-end pressure/chip shielding and 29CFR 1910.95(a) for maximum allowable noise exposure.

Unsafe Nozzle

Above is an example of a nozzle that is dangerous.  As you can see, there is only one path where the air can pass through and this path could be blocked.  Other similar types of blow-off devices that would fall into this same group would include copper tubes, flexible lines, and open pipes.  They are dangerous as the compressed air cannot escape if it is blocked by your body or skin.  If operated above 30 PSIG (2 bar), the air from these nozzles could penetrate the skin and create an air embolism within the body, which can cause bodily harm or death.  This is a hazard which can be avoided by using EXAIR Super Air Nozzles and Safety Air Guns.  The nozzles are designed with fins, which allow the air to escape and prevent blockage of the airflow.  So, you can use the EXAIR Super Air Nozzles safely above 30 PSIG (2 bar) and remain OSHA safe.

To counteract the dead-end pressure violation, some nozzle manufacturers create a hole through the side of the nozzle (reference photo above).  This will allow for the compressed air to escape, but now the issue is noise level.  With an “open” hole in the nozzle, the compressed air is very turbulent and very loud.   The CDC reports that in 2007, “82% of the cases involving occupational hearing loss were reported among workers in the manufacturing sector.” Compressed air and pneumatic equipment are significant contributors to the noise exposure. OSHA created a chart to show the maximum allowable noise exposure.  This chart shows the exposure time and noise limits before requiring hearing protection.  The EXAIR Super Air Nozzles, Super Air Knives, and Super Air Amplifiers are designed to have laminar flow, which makes them very quiet.  As an example, the model 1210 Safety Air Gun has a sound level of only 74 dBA, well under the noise exposure limit for 8 hours.

Hearing loss is the best known, but not the only, ill effect of harmful noise exposure. It can also cause physical and psychological stress, impair concentration, and contribute to workplace accidents or injuries.

NIOSH created an overview of how to handle hazards in the workplace.  They call it the Hierarchy of Controls to best protect workers from danger.  The most effective way is by eliminating the hazard or by substituting the hazard.  The least effective way is with Personal Protective Equipment, or PPE.  For unsafe compressed air nozzles and guns, the proper way to reduce this hazard is to substitute it with an engineered solution.

One of the last things that companies think about when purchasing compressed air products is safety.  Loud noises and dead-end pressure can be missed or forgotten.  To avoid any future fines or having to purchase additional personal protective equipment (PPE), it will be less expensive and a preferred safety method to purchase an EXAIR product.  As in that above Hazard Hierarchy of Controls chart, EXAIR products are that engineered solution.  If you would like to improve the safety in your facility, move up to an engineered solution, and reduce energy costs; an Application Engineer at EXAIR can review your current blow-off devices.  Remember, safety is everyone’s responsibility. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb