Pressure Regulators

At EXAIR, a large part of my job is to discuss your applications and make recommendations based upon which of our products would best help your application. In doing so, we always review your air supply to ensure that you have enough air to run our products. For instance you may need an Air Nozzle. This seems simple enough right? Surely you have enough air for this? Well, if you are buying our Atto Super Air Nozzle (left) you probably do, as this is a small nozzle that consumes 2.5 SCFM. However, you may need our large Super Air Nozzle Cluster (right) that will consume 168 SCFM. So as you can see it’s important that we discuss the amount of air you have at the point of use.

Another part of my job is to help customers trouble shoot issues once they have installed our products. I can proudly say that rarely is it an issue with the product itself. The most common cause of malfunction is with the air supply at the point of use. I have seen companies with massive air compressors not be able to supply 30 SCFM. Why? Well just because you have a lot of air coming out of the compressor, doesn’t mean you have a lot of air at the point of use. Other machines and tools down the line, as well as leaks and turns may have depleted the air supply long before it reaches your station for this application. This is the reason why we always recommend our Pressure Regulators with Gauge as seen here:

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

It’s pretty obvious why we would want you to have a gauge at the point of use, but the importance of the pressure regulator is many times overlooked. Many of our products need to have a certain pressure of air along with the proper SCFM to function efficiently. Some of these are products include some of our Industrial Housekeeping Products and Cabinet coolers. But, many of our products will function perfectly, and even be more efficient for your application with less airflow and psi. To find the best pressure and flow, we use a rule of thumb of starting at 80 psig and dial it back (or up) 5 psig at a time, until the best fit is found.

Most facilities have airlines running throughout, and they are all pushing the same psi and airflow. It is easy to just tap in and drop a line to the new point of use for the new tool. But, if there are 10 machines in line before this one, the air supply at machine 1, is much more than at machine 10. There are also leaks, turns, buildup in the line, and other air flow restrictions that are most likely in the way… This is why you will need a gauge and a pressure regulator at each point of use…

Also, when you drop a line to run a Super Air Knife (or any other EXAIR product) it may be coming off of a 100 psig line. You may only need 40 psi to run this 12″ Super Air knife. At 40 psig you will be pushing 21 SCFM. If this can clean, dry, or move your material as needed, then why use the 100 psig coming from the shop line? At 100 psig, that same 12″ Super Air Knife will use 42 SCFM. That additional SCFM has a rough cost of about $10 per day (running 24 hrs day with cost per kWh at $0.10). As you can see from this simple example, the pressure regulator is a no brainer to save costs and increase efficiency in the product itself.

There are many blogs written about your compressed air being the 3rd to 4th highest utility expense for many companies. In todays economic climate, it is important to use every efficiency possible. Using a regulator is imperative to control any type of flow, be it water, gas, electricity and even – air. Please give us a call to discuss any questions with your next application.

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
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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

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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Turn the Pressure Down, Save Operation Costs

I recently recommended to a customer to turn their air pressure down on their system as low as their process would allow. Meaning regulate the pressure so you have enough to complete the operations needed but find that happy medium where your compressor isn’t working as hard to build those high pressures for no reason!

Compressed air is an amazing tool to have, and when used properly it can be more efficient that other non compressed air tools that run off electricity. How ever its pretty common to see compressed air systems running at their max just because.

Lowering the air system pressure reduces the compressor power consumption by about 1% for every two psi of lower pressure. Lowering the pressure also makes any unregulated operations reduce consumption by almost 1% for every one psi of pressure reduction. Not to mention the extra savings if your compressor system can turn down the compressor power because of the reduced flow and possibly shut off compressors that are no longer needed!

The best pressure at which to set your system is the level where your production can operate efficiently and effectively without waste: There is no right pressure—it depends on your operations and tools. You may have 90 to 100 psig at the compressor, but at the production machine, where the actual work is being done, you could have only 65 to 70 psig. In some cases, it may be even lower due to pressure drops in undersized piping, filters, regulators. The goal is to lower compressor discharge pressure without affecting the the operations at the end of the line.

Having artificially high plant-pressure can help you deal with surges in compressed air demand that might occasionally cause low-pressure and affect production. The higher pressure acts to store reserve air in the various volumes made up of receivers, pipes and such in your system. However, the higher pressure costs more to produce and makes unregulated end uses consume more air, which is an expensive trade-off. Another option is to make sure you have line pressure regulators at each point of use. This will allow you to regulate the operation to the pressure needed being sure to save compressed air and keep the over all system running more efficient.

You can regulate those point of use lines with a number of EXAIRs Pressure Regulators!

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

If we can help size a regulator, or have any other questions on how EXAIR can help you save compressed air in your system please reach out to me or one of our other Application Engineers!

Jordan Shouse
Application Engineer

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