Airflow Update - August 2025

Every month, we share insights to keep you informed about what’s happening in the compressed air industry, from safety reminders and maintenance best practices to market trends, technology updates, and product highlights. Safety is always our top priority, which is why we start each update with a focused Safety Moment to keep best practices top of mind and ensure that everyone goes home safely, every day. Here's our update for August 2025!

Safety Moment

No Horseplay – Compressed Air Can Kill

Compressed air stores a tremendous amount of potential energy. Misuse can be fatal: in one poultry‑plant incident, an employee died after coworkers used compressed air “for horse‑play,” causing abdominal and pelvic trauma (ien.com).

Never point an air hose at yourself or another person, and never use compressed air to clean clothing or skin. These practices can inject air under the skin or into the bloodstream and cause fatal embolisms.

In its safety guidance, EXAIR stresses three fundamentals:

• Personal protection: always wear eye protection (plus face shield, gloves and hearing protection where needed). Never direct compressed air at people; cleaning clothes or skin with compressed air is prohibited. “No horseplay” is non‑negotiable.

• System design: ensure hoses, fittings and tools are rated for compressed‑air pressures; locate shut‑off valves near the point of operation; avoid running hoses across floors to prevent tripping or damage.

• Product specification: use the right blow‑off devices. Hand‑held air guns must limit downstream pressure to 30 psi to comply with OSHA 1910.242(b), and they should have relief paths to prevent “dead‑ending” that can inject air into the body

Maintenance Tips & Best Practices

Optimize Control Strategies

Studies comparing compressor control methods found that switching from load‑on‑load or inlet‑modulation control to variable‑speed drive (VSD) control can cut energy use in part‑load operation.

At 80% of capacity, VSD control can reduce power draw from ~92% down to about 81% of full‑load power.

Eliminate Waste

Eliminating leaks and artificial demand can yield substantial energy savings; reducing operating capacity from 80% down to 40% saved about 25% of full‑load power in one case study.

Regular leak surveys and pressure audits should be part of every maintenance program.

Monitor System Pressure

Installing a pressure‑flow controller helps stabilize plant pressure and avoid artificial demand.

Maintaining a lower, consistent system pressure reduces compressor power requirements and minimizes leaks.

Technology & Innovation Updates

Dual‑flow centrifugal breakthrough

FS‑Elliott released the Polaris P650 DF, an innovative dual‑inlet, double‑flow centrifugal air compressor. Announced on 11 August 2025, the compressor integrates two parallel inlets feeding a single discharge, delivering ISO 8573‑1 Class 0 oil‑free air at up to 20 000 CFM and 30–50 psig, effectively doubling flow capacity while maintaining a compact footprint.

The machine features a split gear case, split bearings, seals and a detachable airend for easy maintenance, and it uses a Regulus R2000 control system to provide touchscreen monitoring, real‑time energy optimization and proactive maintenance notifications.

This high‑capacity, oil‑free design targets applications such as bio‑fermentation, pneumatic conveying, petrochemicals and wastewater aeration.

Battery‑powered portable compressor gains traction

The B‑Air 185‑12, marketed as the world’s first battery‑driven portable screw compressor, continued to garner attention in the U.S. construction sector. An August 26 feature described how the battery‑powered unit eliminates the need for continuous external electricity and offers true autonomy.

Atlas Copco notes that the B‑Air 185‑12’s 57 kWh internal battery enables a full shift of operation, making it suited for road‑construction and fiber‑optic installation where grid power is unavailable.

Company executives highlight the product as a defining moment in the movement toward low‑carbon construction equipment, underscoring Atlas Copco’s pledge to reduce product‑lifetime emissions by 28% by 2030.

Celebrating six decades of manufacturing

Hitachi Global Air Power (formerly Sullair) celebrated its 60th anniversary of air‑compressor manufacturing in Michigan City, Indiana, on 11 August 2025. A company picnic brought together employees, families and international dignitaries. To mark the milestone, Hitachi announced it would fund a public mural in Michigan City that depicts the region’s industrial heritage.

Since Hitachi’s 2017 acquisition of Sullair, more than $45 million has been invested in the Michigan City plant, which now employs over 500 people.

Company leaders used the event to reaffirm their commitment to electric and oil‑free compressor technologies and to highlight ongoing environmental restoration projects at the campus.

Industry & Market Insights

North American rental market keeps booming

A new Research & Markets report released on 25 August 2025 showed that the North American air‑compressor rental market reached nearly $1.8 billion in revenue in 2024 and is projected to reach $2.6 billion by 2031.

Growth drivers include the surge in oil‑ and gas‑sector demand, reshoring of U.S. manufacturing, and large infrastructure initiatives. Oil‑flooded compressors still dominate rentals for construction and general manufacturing, but oil‑free units are gaining share in the food, pharma and petrochemical sectors.

The report notes emerging “Air‑as‑a‑Service” business models and growing adoption of IoT‑enabled smart compressors that allow remote monitoring and improved energy efficiency.

Price pressures remain moderate

The Producer Price Index (PPI) for air‑ and gas‑compressor manufacturing continued to edge higher; FRED data show the industry index at 371.550 in July 2025 (base year 1984 = 100).

The sub‑index that specifically tracks air and gas compressors and vacuum pumps stood at 395.153 in July 2025. These monthly indices provide a quick gauge of inflationary pressures on compressor components and finished goods as we await the September release of August data.

Events & Training

DOE Better Plants Virtual Training (Aug 19–21, 2025)

The U.S. Department of Energy’s Better Plants program hosted an online training focusing on compressed‑air systems. Sessions covered leak detection, sizing, VSD controls and waste‑heat recovery. Materials and recordings are available on the Better Buildings Solution Center.

Best Practices Expo & Conference (Oct 2025)

Registration is open for the fall conference in Atlanta. Highlights will include workshops by the Compressed Air Challenge (now part of CAGI), vendor exhibits and hands‑on training on monitoring and energy auditing.

Staying informed and proactive keeps our teams, facilities, and customers running safely and efficiently. From safety reminders to technology advancements and industry updates, our goal is to keep you equipped with the knowledge you need to succeed. If there’s a topic you’d like to see covered in future updates, or a success story worth sharing, let us know, because continuous improvement starts with open communication and shared insights.

Sources:

Market & M&A

“North American Air Compressor Rental Market, valued at USD 1.8 B in 2024, projected to USD 2.6 B by 2031”, Research & Markets
https://www.researchandmarkets.com/report/north-america-compressor-rental-market Grand View Research+9Research and Markets+96Wresearch+9

“North American Air Compressor Rental Market – Emerging ‘Air‑as‑a‑Service’ Models”, Yahoo Finance
https://finance.yahoo.com/news/north-american-air-compressor-rental-131200245.html Yahoo Finance

“Ingersoll Rand acquires Termomeccanica Industrial Compressors and Adicomp”, AirBestPractices
https://www.airbestpractices.com/industry-news/ingersoll-rand-acquires-termomeccanica-industrial-compressors-and-adicomp Standard Pneumatic Products, Inc.+15Yahoo Finance+15Compressed Air Best Practices+15 (Note: Combined sections for simplicity)

Technology & Innovation

“FS‑Elliott Unveils Polaris P650 DF, Combining Dual‑Flow Capability with Compact Efficiency”, FS‑Elliott press release (July 30, 2025)
https://www.fs-elliott.com/press-release/fs-elliott-p650-df-launch fs-elliott.com+7fs-elliott.com+7fs-elliott.com+7

“FS‑Elliott Launches Adaptive, Compact Centrifugal Air Compressor Polaris P650 DF”, Turbomachinery Magazine (Aug 11, 2025)
https://www.turbomachinerymag.com/view/fs-elliott-launches-adaptive-compact-centrifugal-air-compressor-polaris-p650-df Compressed Air Best Practices+8Turbo Machinery Magazine+8fs-elliott.com+8

“P650 DF: Double‑Flow Oil‑Free Compressor | FS‑Elliott”, FS‑Elliott blog post (July 31, 2025)
https://www.fs-elliott.com/blog/the-benefits-of-double-flow-introducing-p650df fs-elliott.com+5fs-elliott.com+5fs-elliott.com+5

Energy & Efficiency

“Five Energy‑Saving Tips for Compressed Air Systems”, POWER Magazine (citing DOE: over $5 billion/year, 20–50% savings)
https://www.powermag.com/five-energy-saving-tips-for-compressed-air-systems/ Succession Business+6POWER Magazine+6industrialairpower.com+6

“Energy Saving Tips: Best Practices from the U.S. Department of Energy”, Industrial Air Power blog (reiterating DOE figures)
https://www.industrialairpower.com/blog/compressed-air-energy-saving-tips/ Fluid-Aire Dynamics+13industrialairpower.com+13Fluid-Aire Dynamics+13

“2025 JCP&L Compressed Air Incentives in New Jersey – Custom Incentives at $0.30 per kWh”, Fluid‑Aire Dynamics (Aug 11 2025)
https://fluidairedynamics.com/blogs/articles/central-power-light-compressed-air-incentives Plant Engineering+15Fluid-Aire Dynamics+15Incentive Rebate 360+15

“2025 Jersey Central Power & Light Commercial Rebate Guide – Custom rebates up to $0.30/kWh”, EnergySaveNJ (PDF)
https://bizsolutions.energysavenj.com/wp-content/uploads/2025/07/JCPL_Energy_Solutions_CI_Guide.pdf JCPL Bizsolutions+3JCPL Bizsolutions+3JCPL Bizsolutions+3

“2025 ComEd Compressed Air Energy Incentives – Prescriptive incentive: $220 per HP for VSD compressors”, Fluid‑Aire Dynamics
https://fluidairedynamics.com/blogs/articles/comed-compressed-air-energy-incentives comed.com+10Fluid-Aire Dynamics+10Fluid-Aire Dynamics+10

“Fix‑It‑Now Compressed Air offering – fixed‑price incentive for leak detection & repair”, MEA Alliance (ComEd program)
https://www.meeaconference.org/awards/2021-innovation-comed-energy-efficiency-program meeaconference.org

Regulatory

“New DOE Air Compressor Regulations (effective Jan 10, 2025)”, AirBestPractices
https://www.airbestpractices.com/standards/energy-management/new-doe-air-compressor-regulations GovInfo+4Compressed Air Best Practices+4Sullivan-Palatek+4

“10 CFR § 431.345 – Energy Conservation Standards and Effective Dates (DOE rule)”, eCFR
https://www.ecfr.gov/current/title-10/chapter-II/subchapter-D/part-431/subpart-T/section-431.345 GovInfo+3eCFR+3Legal Information Institute+3

“DOE Standards compliance effective Jan 10 2025 (some states previously adopted)”, Sullivan‑Palatek white paper PDF
https://www.sullivan-palatek.com/wp-content/uploads/2024/01/AirFlowInsights.pdf Sullivan-Palatek

Industry Initiatives & Milestones

“The Compressed Air Challenge joins forces with CAGI as its new education foundation”, AirBestPractices
https://www.airbestpractices.com/industry-news/the-compressed-air-challenge-joins-forces-with-the-compressed-air-gas-institute-as-its-new-education-foundation compressedairchallenge.org+6Compressed Air Best Practices+6compressedairchallenge.org+6

“About – Compressed Air Challenge” (mission, energy efficiency training)
https://www.compressedairchallenge.org/about/ GovInfo+12compressedairchallenge.org+12Standard Pneumatic Products, Inc.+12

“Compressed Air Challenge – Fundamentals Training (15–25% savings)”
https://www.compressedairchallenge.org/fundamentals compressedairchallenge.org