Tag: programmable air control

Stop Starving Your Tools: How to Beat Pressure Drop in Compressed Air Systems

Published on by Al WooffittLeave a comment

If you’ve ever noticed your pneumatic tools losing their “punch” or your machines throwing low-pressure faults, you’re likely dealing with the silent thief of industrial efficiency: pressure drop.

Pressure drop is the reduction in air pressure from the compressor discharge to the actual point of use. It’s not just a performance issue; it’s an expensive energy drain. Most facilities try to fix it by cranking up the compressor pressure, which is like trying to fix a leaky garden hose by turning the spigot up—it just wastes more energy and stresses the system.

Here is how to tackle it and how EXAIR products help you win the fight.

1. Size Matters (The Piping Dilemma)

The most common cause of pressure drop is undersized piping. Think of your compressed air system like a highway; if you try to cram 1,000 cars into one lane, traffic slows down.

  • The Fix: Always size your main headers and distribution lines for the maximum potential flow, not just your current average. Using a “loop” system instead of a single “dead-end” header allows air to flow in two directions to reach a high-demand tool, effectively doubling the capacity of the pipe.

2. Smooth Out the “Plumbing”

Every elbow, tee, and valve creates friction. Standard plumbing fittings often have sharp turns that create turbulence, slowing down the air.

  • The Fix: Minimize the use of 90-degree elbows where possible (use long-radius sweeps instead) and ensure you aren’t using restrictive, undersized quick-connect couplings at the tool.

3. Eliminate the “Spiky” Demand

Large, intermittent air consumers can cause the pressure in the entire line to “sag.”

  • The Fix: Use a receiver tank (surge tank) near the point of high demand. This acts as a local battery, providing the necessary volume instantly without pulling from the main header and causing a system-wide drop.

How EXAIR Combats Pressure Drop

EXAIR is built on the philosophy of “doing more with less.” Our products are engineered specifically to maximize force while minimizing air consumption, which is the most effective way to reduce pressure drop at the end of the line.

Engineered Super Air Nozzles

EXAIR Nozzles

Standard “open pipe” blowoffs are air hogs. They create massive localized pressure drops because they dump huge volumes of air inefficiently. EXAIR Super Air Nozzles use a small amount of compressed air to entrain large volumes of surrounding “free” room air.

  • The Result: You get high-velocity discharge with significantly lower compressed air demand, keeping the pressure stable for the rest of your tools.

Digital Flowmeters

You can’t fix what you can’t measure. EXAIR Digital Flowmeters allow you to see exactly where the air is going in real-time. By monitoring different zones of your plant, you can pinpoint exactly which branch or machine is causing the pressure drop, making it easy to identify leaks or bottlenecks.

Precise Pressure Regulators

Using more pressure than a process requires (artificial demand) is a leading cause of system-wide drops. EXAIR Pressure Regulators ensure that each application gets exactly the PSI it needs and nothing more. By lowering the pressure at the point of use to the minimum required, you preserve the “headroom” in your main lines.

The Bottom Line, combating pressure drop is about velocity and volume. By optimizing your piping layout and switching to high-efficiency end-use products like our intelligent, point-of-use compressed air products, you stop starving your tools and start saving on your electric bill.

If you’re ready to stop turning up the compressor, and start fixing the flow, give us a call!

Al Wooffitt
Application Engineer

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Step 3: Upgrade Your Blow off, Cooling, and Drying Operations

Published on by Al WooffittLeave a comment

In the world of manufacturing, compressed air is often called the “fourth utility.” It’s essential, but it’s also expensive to produce. If you’re following the Six Steps to Optimize Your Compressed Air System, Step 3 is where you stop the bleeding.

Step 3, dear reader, is the subject of today’s blog.

Upgrading your blow-off, cooling, and drying operations from “homegrown” solutions to engineered products is one of the fastest ways to slash energy costs and improve plant safety.

The Problem with “In-House” Solutions

Many plants rely on makeshift blow-off devices: crimped copper tubes, pipes with drilled holes, or basic air nozzles found at a hardware store. While they seem “free” or cheap, they are incredibly inefficient.

  • High Air Consumption: They lack the physics to move air efficiently, requiring massive volumes of compressed air to do the job.
  • Dangerous Noise Levels: Drilled pipes produce a high-pitched shear that often exceeds OSHA noise exposure limits.
  • Safety Hazards: If a pipe or open tube is dead-ended against skin, it can lead to serious injury or air embolism.

The Engineered Solution: EXAIR Technology

This is where EXAIR engineered compressed air products change the game. Unlike a standard pipe, EXAIR products use the Coanda effect to “entrain” the surrounding room air. For every part of compressed air used, an EXAIR nozzle or air knife pulls in 30 to 40 parts of “free” ambient air.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

If you are drying a conveyor belt or cleaning wide sheets of material, a drilled pipe is a money pit. An EXAIR Super Air Knife provides a high-velocity, uniform sheet of air across the entire surface. It’s quiet (around 69 dBA for most applications) and reduces air consumption by up to 80% compared to open headers.

For targeted blow-off or part ejection, Super Air Nozzles replace open tubes and cheap nozzles. They provide a forceful, concentrated stream of air while meeting OSHA requirements for skin pressure and noise. You get more “push” for significantly less “psi.”

Step 3 isn’t just about blowing air; it’s about optimizing how air manages temperature and waste. From Vortex Tubes that provide spot cooling without refrigerants to Air Amplifiers for smoke and fume removal, these tools ensure you aren’t overworking your compressors for simple tasks.

The Bottom Line

Upgrading to EXAIR engineered products isn’t just a maintenance fix; it’s a financial strategy. Most facilities see a return on investment (ROI) in just weeks through reduced energy bills.

By replacing inefficient, loud, and dangerous blow-off methods with engineered solutions, you’re not just optimizing your compressed air—you’re creating a quieter, safer, and more profitable shop floor.

Al Wooffitt
Application Engineer

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Finding and Fixing Compressed Air Leaks

Published on 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 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.

  1. 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.
  2. 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.
  3. 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.
  4. 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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