Compressed air is one of the most expensive utilities in any industrial facility; yet it’s also one of the most commonly wasted. Many systems run at higher pressures than necessary, driving up energy costs and increasing air consumption without improving performance.
That’s where EXAIR pressure regulators come in.
What is a Pressure Regulator?
A pressure regulator is a simple but powerful device that controls and stabilizes air pressure delivered to your application. Installed at the point of use, it allows you to “dial in” the exact pressure needed—no more, no less.
Inside the regulator, a spring and diaphragm system automatically adjusts airflow to maintain a consistent downstream pressure, even when supply conditions change.
Why Running at Full Pressure is Costing You
It’s common for compressed air systems to operate at full line pressure—often around 100 PSIG—even when the application doesn’t require it. The problem? Higher pressure directly increases air consumption and energy usage.
For example:
- Reducing pressure from 100 PSIG to 80 PSIG can cut air consumption by nearly 20% and reduce power usage by about 10%.
- Lowering pressure even further at the point of use can deliver 30%+ air savings in certain applications.
In short: if you don’t need the pressure, you’re paying for wasted air.
How EXAIR Pressure Regulators Save Air
1. Control at the Point of Use
Instead of running your entire system at one high pressure, EXAIR regulators let you fine-tune pressure exactly where it’s needed. This ensures each application operates at its optimal setting—not the system maximum.
2. Reduce Air Consumption Instantly
Pressure and airflow are directly related. When you lower pressure, you automatically reduce the volume of compressed air consumed.
A simple adjustment—turning down a regulator—can immediately lower SCFM usage without changing equipment.
3. Improve System Efficiency
Lower pressure reduces the workload on your compressor. In fact, decreasing system pressure can reduce compressor energy consumption by measurable margins, helping extend equipment life and reduce maintenance.
4. Eliminate Overuse and “Set-It-and-Forget-It” Waste
Without regulators, operators often compensate by increasing pressure “just to be safe.” Regulators remove that guesswork by locking in the correct pressure for consistent, repeatable performance.
Real-World Example
Let’s say an air knife application runs at 100 PSIG and consumes 42 SCFM. By reducing pressure to 60 PSIG:
- Air consumption drops to 27.6 SCFM
- That’s a 34% reduction in compressed air usage—with no loss in performance if the application still meets requirements.
Multiply that across multiple applications, and the savings add up quickly.
The Bottom Line
If your compressed air system is running at full pressure everywhere, you’re almost certainly wasting energy and money.
EXAIR pressure regulators provide a straightforward solution:
- Lower pressure where possible
- Reduce air consumption instantly
- Improve overall system efficiency
Sometimes, the easiest way to save compressed air isn’t changing your equipment—it’s simply turning down the pressure.
| 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. |
Pressure regulator image courtesy of AutomationForum.co via Creative Commons
