By initiating a LeekSeek leakage detection program you are not only discovering leakages. You are assisted in finding areas in which to reduce air consumption and noise level. Generally, optimizing the compressed air system could represent as much as 30% of the savings potential in the system. It is fully possible to reduce air consumption and noise level with maintained blowing force. A combination which may seem unlikely but with the use of the right technology, it is possible to achieve. This is an area of the compressed air system that is often overlooked. Many of these solutions have a pay-back period that often is measured in weeks. LeekSeek ™ do not sell or market products. We will however recommend methods and solutions that will reduce your air consumption and be glad to direct you to the specialists that market these that can give you further technical support.
There are some rules of thumb for quieter and less energy demanding blowing.

1. Reduce the pressure and decrease blowing distance
Decrease the amount of air as much as possible. In most cases more air than necessary is used to create the required blowing force. The noise level and air consumption can then be reduced significantly.

2. Avoid blowing against sharp edges etc.
If possible direct the air stream so that it strikes just past edges, holes and other sharp irregularities in machines, products and alike.

3. Use several blowing nozzles if the blowing force must be increased
From an acoustic point of view it is preferable to increase the blowing force against an object by using an additional nozzle rather than raising the amount of air passing through an existing one. Direct the nozzles towards those parts of the object where the greatest effect is achieved. Installing an additional identical nozzle creates a noise level of approx. 3dB (A). Doubling the blowing force through a straight pipe nozzle raises the level by 6-8 dB(A). One should also keep in mind that an increase in pressure of one bar increases the energy consumption by approximately 8 percent!

4. Blow only when necessary
Shut off the air supply during breaks in the work. It decreases the noise and saves air. When blowing is only necessary in certain phases of a machining process, such as for example in punch presses, a valve can be regulated by a cam so that it only opens at the right time interval - so called impulse blowing

Some solutions that will reduce your air consumption

Air knives
What is an air knife ?
An air knife uses the coanda effect to create air motion in its surroundings. Using a small amount of compressed air as a power source the knife pulls in large volumes of surrounding air to produce a high flow, high velocity curtain of air. It is en energy efficient way to clean, dry or cool parts or product and will typically reduce the noise level by half. Air savings of 40% to 90% are possible when replacing “homemade” blowoff devices.

Air nozzles
How air nozzles work
The most common type of "nozzle" used in compressed air blowing is the open pipe. In many cases the opening has been flattened. The dimensions of the pipe may vary from a few millimeters up to one inch in diameter. In most cases no technical dimensioning has preceded the installation. People have simply chosen a pipe that they are confident is big enough to perform the blowing operation. The result is normally an over dimensioning of the blowing force.
As a result of extensive testing we have been able to compile a table showing how a technically developed nozzle is able to maintain blowing force yet make considerably less noise and consume less air. It is part of the LeekSeek technicians work to identify pipes and nozzles that can be replaced by more economical alternatives. Finding only a few applications warrants his costs which the following table exemplifies.

Possible savings with an air nozzle instead of an open pipe

It important to remember that these savings are possible with maintained blowing power. The figures are based on a pressure of 5.5 bar and a cost of € 0.020 per cbm. It is possible you are using higher pressure and that your cost per cbm also is higher. An increase of 1 bar increases the energy consumption by 8 %.

Air amplifiers
Air amplifiers pull in large volumes of surrounding air to produce high volume, high velocity outlet flows. They are considerably more quiet than an open pipe alternative and can be used to – dry wet parts, cool hot parts, clean machined parts, ventilate confined areas, exhaust tank fumes.

Air volume that can be achieved using an air amplifier

Super air nozzle cluster
Some applications require extremely high force with extensive reach. Air nozzle cluster provide incredibly strong blowing force. They are ideal for part ejection as well as blowoff, cooling and drying applications.

These Air cluster nozzles are also available in hand held versions with an easy top operate manual valve.

Micro Air nozzles
Even what appears as smaller dimensions of pipe used considerably more air than you would expect.
So called micro nozzles allow precision blowoff for a directed high volume, high velocity airflow.
Sound level and air consumption is low.