Kaishan USA | August 6, 2025 | Uncategorized
To operate effectively, impact wrenches must receive compressed air at the pressure specified by their manufacturer.
If your compressed air system is not delivering the 90-PSIG or 100-PSIG your impact wrench requires, it will operate more slowly. It may not have enough torque to tighten or loosen bolts as required. If it’s tightening the lug nuts on a wheel, they could loosen and allow it to come off, potentially resulting in damage or injury. All because the tool was not receiving the required air pressure.
The same is true of almost all air tools. And, unfortunately, the go-to solution for all-too-many maintenance workers—increasing the pressure output of their rotary screw compressor—is often a bad idea.
Here’s why. Because of the inverse relationship between pressure (PSIG) and flow (CFM), trying to increase the pressure at a remote end-use by boosting the pressure your compressor outputs probably will produce less air at the targeted application. And, most of the time, when a user says he’s not getting enough pressure to run his impact wrench, it’s a problem of flow, not pressure.
In addition, compressed air suffers from the Goldilocks syndrome: “too much” is just as bad as “not enough.” So the primary challenge in managing a compressed air system is getting it “just right.” And keeping it there.
You want to avoid both extremes:
We have covered the compressor side of the low-pressure problem, discussing “What To Do When Your Air Compressor Is Not Building Pressure.”
This post goes into more detail on the importance of avoiding low pressure, explaining what happens at the end of the line. To the applications, tools and work products that aren’t getting the pressure they need.
We’ll start with the impact on the tools themselves.
When the compressed air your system delivers does not reach the level recommended by the tool manufacturer, an air tool will not work correctly. The following problems will arise:
In one past example, a plant suffered a power failure. And while the electricity was off for the entire plant, a computer numerical control machine powered by compressed air continued to operate, using compressed air stored in receiver tanks. That’s the good news.
The bad news was that the machine’s clamps gradually lost power as the air pressure dwindled. As a result, the workpieces weren’t held as tightly and began to move and shift slightly, not a good thing for precision machining. As a result, all the workpieces had to be scrapped.
Nowadays, CNC manufacturers typically install pressure regulators on their machines to keep pressure within design parameters.
It’s essential that computer numerical control machines receive compressed air at the exact pressure specified by their manufacturer.
The main reason a device is underperforming, of course, is that it’s not getting enough air pressure. For some reason.
But you make a serious mistake if you immediately increase the pressure the compressor is providing.
Here’s why: First, as mentioned, because of the inverse relationship between flow and pressure, increasing the compressor’s output pressure decreases the flow. And there are other reasons why an end-use is not performing well:
As a result, you’ll want to follow a logical process to determine the cause of the problem.
Rather than immediately raising the pressure at your compressor, you’ll want to eliminate other possible causes. If you’re finding your air tools are underperforming, follow this process:
Only then should you increase the pressure provided by your compressor. Remember, however, that increasing pressure for the entire system can significantly raise your electricity costs. As mentioned, we discuss this topic more fully in our post, “What To Do When Your Air Compressor Is Not Building Pressure.”
Depending on the pressure requirements of each machine, you can use a pressure regulator as close to the tool as possible to maintain the correct pressure. A regulator also helps make the tool last longer.
A regulator located as close as possible to an air tool can ensure it gets the required pressure.
If low pressure is a recurring issue for your compressed air system, an audit by a compressed air professional will help you determine the best way forward.
For low-pressure issues, an audit can help you determine how large your system needs to be. Too many companies size their compressors assuming the worst-case scenario—that all their machines are running continuously. An audit will list all the tools on the demand side, assess their utilization and determine the right mix of compressors and storage that will meet your needs.
An audit also will help you identify and deal with issues such as proper sizing, rapid cycling, energy conservation, poor performance, leaks, low air quality, shortened lifespans and more.
In one outstanding example, Iowa Pump and Compressor, an independent distributor, conducted an air audit and ultimately saved its customer, Progressive Foundry, $23,000 in electricity costs. It’s just one of many success stories on our case study web page outlining the benefits of an air audit by a qualified compressed air professional.
That’s why it is so crucial for Kaishan USA to partner with a nationwide network of independent distributors, who can provide on-site help and consultation as needed.
Audits conducted by these factory-trained air compression experts can help you achieve broader objectives, such as reducing downtime, lowering costs or developing a comprehensive maintenance program. We see the benefits of those audits every day.
Plus, our distributors can service your air compressor system without a problem. And they have staff members who are skilled in advanced technology. We partner with these independent, local distributors because it's the best way to provide expert guidance, faster response times and personalized support tailored to your needs. Their job is not just to sell compressors, it’s to build relationships, ensuring you get the right system, reliable service and quick access to parts when you need them most.
They have factory-trained technicians with a deep understanding of industrial applications, helping you maximize efficiency and minimize downtime. When you buy through Kaishan, you're getting more than a product—you're getting a local partner who cares about your business and will do what they can to help you succeed.
Delivering the required air pressure is crucial to the operation of your compressed air system and all the processes and air tools that rely on it. If you need help ensuring all your end uses have the air pressure they need, get in touch with the experts at Kaishan. Contact us today.
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