In the food industry, compressed air is an essential resource used for processes such as drying, blowing, surface cleaning, rapid cooling, and packaging handling. However, many facilities still rely on improvised solutions: open copper tubes, pinched hoses, repurposed liquid spray nozzles, or refrigeration lines used as blowoff tools.

Although these practices may seem inexpensive and functional, they often come with a high energy cost, create operational risks, and directly affect the overall efficiency of the compressed air system. The proper technical alternative is to use nozzles specifically designed for compressed air—ensuring efficiency, safety, and regulatory compliance.

Why replace improvised solutions?

Even if homemade adaptations appear convenient, they tend to create negative impacts in three critical areas:

1. Excessive energy consumption

Nozzles not engineered for compressed air typically consume more SCFM than required, increasing the load on the central system, raising electrical consumption, and accelerating compressor wear.

2. High noise levels

Uncontrolled air flow can exceed 90 dBA, making hearing protection mandatory under OSHA regulations. It also contributes to a more stressful and noisy work environment.
EXAIR’s Digital Sound Level Meter (DSLM) is an easy-to-use instrument that helps measure and monitor noise levels across a wide range of industrial environments.

3. Safety and product risks

Many improvised solutions fail to properly control pressure and outlet force, posing risks to personnel or products—especially when there is direct contact.

Real Technical Case: Small Changes, Big Savings

A food packaging plant was using liquid spray nozzles to dry plastic bags after rinsing. These nozzles consumed 17.5 SCFM at 75 PSI and generated 91.2 dBA of noise. After an efficiency assessment, they were replaced with EXAIR Model 1100 compressed air nozzles, made from 316 stainless steel with a standard ¼” NPT connection.

Technical results:

• Reduced consumption: 13.3 SCFM
  
• Savings per nozzle: 4.2 SCFM
  
• Noise reduction: from 96 dBA to 78 dBA
  
• Nozzles installed: 3
  
• Annual operating hours: 7,000 h
  
• Estimated energy cost: $0.10 USD/kWh
  

Estimated annual savings: $1,645.52 USD
Initial investment: $294 USD
Return on Investment (ROI): 65 days

Technical Advantages of EXAIR Nozzles

Efficiency by design

Super Air Nozzles draw in ambient air to amplify the output flow while using less compressed air. This results in lower SCFM consumption, reduced electrical expense, and less load on the compressed air system.

Operational noise reduction

Their aerodynamic design minimizes turbulence and controls flow expansion, keeping sound levels below 80 dBA. This eliminates the need for hearing protection and improves overall working conditions.

Hygienic and durable materials

Built from 316 stainless steel, these nozzles withstand intensive sanitation processes, chemical exposure, and food-contact environments. They are ideal for applications with humidity, high temperature, or frequent washdown.

How to Implement These Improvements

One major benefit is that no system redesign is required. The nozzles can be installed easily using standard threaded connections (¼” NPT), allowing integration within minutes. No control changes or long downtime are needed.

Recommended steps:

• Audit current points of use
  
• Measure consumption with a flow meter (e.g., EXAIR’s Digital Flowmeter)
  
• Compare current flow vs. projected flow with new nozzles
  
• Calculate the expected return on investment
  
• Install and verify results through monitoring

Conclusion: Real Efficiency for Real Applications

Investing in compressed air nozzles engineered for industrial use not only reduces energy consumption—it also improves worker safety, lowers noise levels, prevents unnecessary system wear, and delivers very fast ROI.

In industries like food processing—where hygiene, efficiency, and safety are top priorities—these small technical improvements represent a significant step toward a more competitive and reliable plant.

Trust the experts at Airtec and take your industrial compressed air systems to the next level!

CONTACT US! Our experts will provide you with the best alternative for your business.