6 Steps to Optimizing Compressed Air: Turn it Down!!!

TURN IT DOWN!!! My wife screamed at 6:00am the morning of our first NFL Sunday. As a lifelong Cincinnati Bengals fan, it’s been a tradition in our house for me to wake everyone up while blaring Guns N’ Roses “Welcome to the Jungle” first thing in the morning each and every week 1. After 13 years together you’d think she would be prepared for this by now, but I still get her every time.

You may also hear your maintenance manager screaming to turn it down while out in the shop. They’re not talking about music volume. They’re more concerned about the compressed air pressure you’re using.

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. 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.

Pressure Regulators “dial in” performance to get the job done without using more air than necessary.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, 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.

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

YouTube. (2009). YouTube. Retrieved September 21, 2022, from https://www.youtube.com/watch?v=o1tj2zJ2Wvg.

Optimization:  Step 6 – Control the air pressure

Since air compressors use a lot of electricity to make compressed air, it is important that you use it as efficiently as possible.  EXAIR generated a chart with six simple steps to optimize your compressed air system.  Following these steps will help you to cut overhead costs and improve your bottom line.  In this blog, I will cover the sixth step; controlling the air pressure at the point of use.

Pressure Regulators

One of the most common pressure control devices is called the Regulator.  It is designed to reduce the downstream pressure that is supplying your system.  Regulators are commonly used in many types of applications.  You see them attached to propane tanks, gas cylinders, and of course, compressed air lines.  Properly sized, regulators can flow the required amount of gas at a regulated pressure for safety and cost savings.

EXAIR designs and manufactures compressed air products to be safe, effective, and efficient.  By replacing your “old types” of blowing devices with EXAIR products, it will save you much compressed air, which in turn saves you money.  But, why stop there?  You can optimize your compressed air system even more by assessing the air pressure at the point-of-use.  For optimization, using the least amount of air pressure to “do the job” can be very beneficial and practical.

Model 1100

Why are regulators important for compressed air systems?  Because it gives you the control to set the operating pressure.  For many blow-off applications, people tend to overuse their compressed air.  This can create excessive waste, overwork your air compressor, and steal from other pneumatic processes.  By simply turning down the air pressure, less compressed air is used.  As an example, a model 1100 Super Air Nozzle uses 14 SCFM of compressed air at 80 PSIG (5.5 bar).  If you only need 50 PSIG (3.4 bar) to satisfy the blow-off requirement, then the air flow for the model 1100 drops to 9.5 SCFM.  You are now able to add that 4.5 SCFM back into the compressed air system. And, if you have many blow-off devices, you can see how this can really add up.

In following the “EXAIR Six Steps To Optimizing Your Compressed Air System”, you can reduce your energy consumption, improve pneumatic efficiencies, and save yourself money.  I explained one of the six steps in this blog by controlling the air pressure at the point of use.  Just as a note, by reducing the pressure from 100 PSIG (7 bar) to 80 PSIG (5.5 bar), it will cut your energy usage by almost 20%.  If you would like to review the details of any of the six steps, you can contact an Application Engineer at EXAIR.  We will be happy to help. 

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

When Accessories Become Essentials

In my almost three decades of home ownership, I’ve learned a great deal about maintenance in regard to dwelling structures. Among those lessons are:

  • The importance of the right tool(s) for the job.
  • Having the right materials on hand (I’m looking at you, every plumbing project I’ve ever attempted).
  • When it’s a one-person job, a team effort…or a call to the professionals is always in play.

When it comes to EXAIR Intelligent Compressed Air Products, the first and last concerns above are easily addressed. With precious few exceptions, basic hand tools are all that’s required for installation or maintenance, and they’re engineered & manufactured to be “user friendly”. One key aspect of the “user friendliness” is a comprehensive inventory of accessories.

Some of these accessories are unique to a particular Product Line:

  • Air Knife Plumbing Kits are great, especially for the longer Super Air Knives that need to be plumbed to multiple ports along their length. These consist of air hose and brass fittings (for Aluminum Super Air Knives) or Stainless Steel tubing and fittings (for the Stainless Steel models) that connect in to those multiple ports, allowing for infeed to just one (for Super Air Knives up to 54″ long) or two (for lengths up to 108″) 1/2 NPT fittings. These can actually be used on our Super Ion Air Knives as well.
  • Universal Air Knife Mounting Systems provide for ease of installation, and precise positioning of our Aluminum or Stainless Steel Super, Standard, or Full Flow Air Knives.
  • Coupling Bracket Kits can join Super Air Knives together for a continuous, uninterrupted curtain of air flow in any length that you need. They can also be used if you don’t always need air flow along the entire length of a Super Air Knife assembly. I had the pleasure of assisting a user once who had needed to blow off parts on a hanging conveyor. Some parts were a little under 2ft long; others were about 4ft long. They used the Model 110900 Coupling Bracket Kit to join two Model 110024 24″ Aluminum Super Air Knives together, plumbed them separately, and turned both of them on for the long parts, and just the ‘top’ one for the shorter parts.

Other accessories can be used for a variety of products:

  • Stay Set Hoses (with or without Magnetic Bases) make up instant Blowoff Systems when used with our engineered Air Nozzles. They come in lengths from 6″ to 36″, and can bent by hand to “stay set” (as advertised) to hold their position. They can repositioned, as needed. They’re also popular for use with our 3/4″ and 1-1/4″ Super & Adjustable Air Amplifiers, and can even be used with 3″ Air Knives.
  • Conveyance Hose is a great way to connect point A to point B in a Line Vac Air Operated Conveyor system. Bulk material conveyance really doesn’t get much easier than Line Vac + Hose = Instant Conveyor System (just add compressed air). It can also be used with our Air Amplifiers to duct or route the air flow on the inlet, or the outlet to, or from, one area to another.
  • Mounting Brackets are available for a number of our products:
    • Atomizing Spray Nozzles
    • Line Vacs
    • Filters and Regulators
    • Cabinet Cooler System Thermostats
  • Vacuum Cups are often used with our E-Vac Vacuum Generators for pick-and-place material handling applications. We stock fittings and push-in tubing as well, to complete the package. Those fittings and tubing can also be used for the liquid supply to our Atomizing Spray Nozzles (depending on what you’re spraying, you might want to verify chemical compatibility first; call me if that’s a concern).

Other EXAIR Compressed Air Product Accessories can be used with products that aren’t even ours, or, in conjunction with your compressed air system design for increased efficiency or flexibility:

  • Model 9500-60 60 Gallon Receiver Tanks can be installed near points of high air flow demand to prevent or limit fluctuations in supply throughout the system.
  • Compressed Air Hoses can be made to length, and a variety of Fittings (Hex or Close Nipples, Couplers, Reducers, Tees, Elbows, Crosses, and Bulkhead Fittings) are on the shelf in popular sizes.
  • Our 5 Micron water/dirt Filter Separators are a standard when needing clean, condensate free air to blow through and end-use product.
  • Pressure Regulators are an important factor to minimize compressed air consumption. EXAIR always recommends operating our products at the minimum pressure necessary for a successful application. For example, if using a Super Air Knife to remove dust and light debris, this could be achieved at 20 PSIG, a Pressure Regulator will provide that adjustability and keep the air consumption much lower than if it were operated at 80-100 PSIG.
  • Swivel Fittings, typically used with compressed air nozzles, provide the precision adjustability to focus in on the exact area you need to treat.

If you have any questions about how the above accessories can aid with your application, please relay on our expert team for answers and solutions. Having the right materials and accessories on-hand can simplify installation, enhance performance, save compressed air, and more!

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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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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