Compressed air is one of the most versatile utilities in industry. It’s used for everything from part drying and debris removal to cooling and conveying. But not all compressed air products are created equal. Too often, I come across shops and plants relying on drilled pipes, open tubes, or cheap plastic nozzles to get the job done. On the surface, these might seem like quick and inexpensive fixes. In reality, they end up costing much more in wasted energy, unnecessary noise, and lost productivity.
Let’s start with drilled pipes and open-ended blow offs, since they’re some of the most common culprits. At first glance, they look like an easy solution. Just drill a few holes, hook up compressed air, and let it blast away. The problem is they waste a tremendous amount of air. They’re also extremely loud, often well above OSHA’s permissible noise levels outlined in 1910.95(a). In many cases, the sound exposure can reach levels that require hearing protection just to operate nearby. Beyond that, drilled holes create a dead-end pressure condition that violates OSHA 1910.242(b), which states that compressed air used for cleaning must be regulated to 30 PSIG if dead-ended. This is a serious safety concern that’s often overlooked until an injury or compliance audit brings it to light (or even worse, an OSHA inspection).
Cheap nozzles and modular coolant hoses being used for compressed air fall into the same trap. They’re not designed to handle the pressures and flows involved in compressed air applications. This means poor performance, higher operating costs, and, in many cases, premature failure. It’s not unusual to see these hoses break down or simply pop off, creating unsafe conditions on the floor. What seemed like a cost-saving shortcut turns into downtime, frustration, and more expense down the road. The high consumption of these devices also leads to pressure drops elsewhere in your compressed air system.
This is where engineered solutions from EXAIR make the difference. Every nozzle, air knife, and air gun is designed with efficiency and safety at the forefront. Engineered nozzles, for example, reduce compressed air consumption while maintaining or even amplifying force. They also dramatically reduce noise levels, often bringing them into full OSHA compliance. Products like the Super Air Knife provide uniform airflow across an entire length while using a fraction of the air compared to drilled pipes.
In a previous blog, we shared an example where a customer was using a ¾” drilled pipe for blowoff on their production line. By replacing it with a 12” Super Air Knife, they reduced their compressed air consumption by over 80 SCFM. At their energy rate, this translated into more than $5,000 in annual savings, with a payback period of just a few months. Not only did they cut their energy bill, but they also eliminated an OSHA noise hazard and brought their system into compliance with dead-end pressure regulations.
When you factor in the rising costs of energy, the difference is not small. Inefficient or inferior products consume more compressed air than necessary, which means compressors work harder, energy bills rise, and maintenance intervals shorten. On the other hand, using an engineered solution is an investment that pays itself back quickly, often in months (or days) rather than years.
With engineered EXAIR products, you’ll improve efficiency, cut costs, reduce noise, and create a safer workplace. The short-term convenience of “cheap and easy” rarely holds up against the long-term benefits of doing it right the first time.
Tyler Daniel, CCASS
Application Engineer/Intl Trade
E-mail: TylerDaniel@EXAIR.com
X: @EXAIR_TD
