Episode 32: Getting Pressure "Just Right"

Jason Reed

Alright, welcome back to The Big Dog Podcast, powered by Kaishan USA. I’m Jason Reed, and as always, I’m here with Lisa Saunders. Today, we’re talking about something that sounds simple but, honestly, trips up more shops than you’d think—getting your air pressure just right. Lisa, you remember your first week in maintenance? Didn’t you have a run-in with this exact problem?

Lisa Saunders

Oh, I absolutely did. I’ll never forget it. I was barely out of orientation, and I thought, “How hard can it be to keep the line running?” Well, turns out, if you mess up the pressure, you can shut down half the plant. I set the regulator too low—like, way too low—and suddenly, impact wrenches were just… sputtering. Bolts weren’t tightening, and we had to stop everything to figure out what was going on. I felt like I was gonna melt into the floor.

Jason Reed

Yeah, and that’s the thing—impact wrenches, and honestly most air tools, are super picky about pressure. They want that sweet spot, usually 90 to 100 PSIG. If you’re under that, you’re not getting the torque you need. You might not even get the speed. And if you’re over it, you’re risking tool damage, safety issues, and just burning money for no reason.

Lisa Saunders

Exactly. It’s like Goldilocks, right? Too much, too little—both are bad. I mean, if you’re running an impact wrench at 80 PSIG, you might as well be using a hand tool. But crank it up to 120, and you’re not just wasting energy, you could actually damage the tool or, worse, create a safety hazard. I read a case where a CNC machine lost clamp pressure after a power outage, and every single workpiece had to be scrapped. All because the pressure wasn’t right.

Jason Reed

And it’s not just about the tools. If you’re running low, you’re losing productivity, you’re risking product quality, and you’re probably spending more on energy because the tool’s running longer to do the same job. And if you go too high, you’re just throwing money away on electricity and repairs. It’s a lose-lose if you’re not dialed in.

Lisa Saunders

Yeah, and I think a lot of folks just assume, “Oh, the tool’s slow, let’s bump up the pressure.” But that’s not always the answer. Sometimes you’re just making things worse. We’ll get into that in a second, but the bottom line is—pressure matters, and getting it just right is the whole game.

Jason Reed

So, let’s talk about what actually causes those pressure problems. I mean, it’s not always the compressor, right? Sometimes it’s what we call the “dirty 30”—that last 30 feet of hose, tubing, and fittings before the tool. You can lose 30, even 50 PSIG right there if things aren’t sized or maintained right. That’s wild.

Lisa Saunders

Yeah, and don’t forget leaks. Even a tiny leak in a fitting or hose can kill your pressure at the tool. Or maybe the hose is too small, or the fittings are gummed up. I always tell people, start at the tool and work your way back. Check the pressure right at the tool first. If it’s good there, maybe the tool needs lube or it’s just worn out. But if it’s low, then you start looking for leaks, bad hoses, or undersized piping.

Jason Reed

And here’s where people get tripped up. I had a plant manager once—good guy, but he thought he could just crank up the compressor to fix everything. So he bumps the system up, thinking more pressure will solve the problem. But because of the inverse relationship between pressure and flow, he actually made things worse. Less air was getting to the end of the line, not more. The impact wrenches were even weaker. It’s like, you gotta check the basics before you start messing with the whole system.

Lisa Saunders

Totally. And if you do need to adjust pressure, do it as close to the tool as possible. Use a regulator right there, not at the compressor. That way, you’re not raising the pressure for the whole plant and running up your electric bill. Plus, the tool lasts longer if it’s not getting slammed with too much pressure all the time.

Jason Reed

And don’t forget, sometimes it’s just a sizing issue. If your system was built for a worst-case scenario—like every tool running flat out, all day—you might be running way more compressor than you need, or you might have bottlenecks you never noticed. That’s where a little troubleshooting goes a long way. Check the tool, check the hoses, check for leaks, and only then think about the compressor settings.

Lisa Saunders

Yeah, and if you’re still stuck, that’s when you start thinking about bringing in the pros. Which, funny enough, is exactly what we’re talking about next.

Lisa Saunders

So, let’s get into audits. I know people hear “audit” and think, “Oh great, more paperwork.” But honestly, a professional air audit can save you a ton of money and headaches. There was that case with Progressive Foundry—after an audit, they saved $23,000 a year just on electricity. That’s not pocket change.

Jason Reed

Yeah, and it’s not just about finding leaks or bad hoses. A good audit looks at your whole system—sizing, demand, storage, even how your compressors cycle. Sometimes you find out you’re running way more pressure than you need, or you’ve got compressors fighting each other. The pros can spot stuff you’d never notice on your own.

Lisa Saunders

And the best part is, when you work with someone like Kaishan’s network of distributors, you’re not just getting a report. You’re getting local support, factory-trained techs, and real help with implementation. They’re not just there to sell you a new compressor—they want your system running right, long-term.

Jason Reed

So, when should you call in the pros? I’d say, if you’re chasing pressure problems more than once or twice a year, or if you’re seeing weird drops you can’t explain, it’s time. Or if you’re about to invest in new equipment and want to make sure your system can handle it. An on-site assessment should give you a clear list of issues, a plan for fixes, and a sense of what you’ll save—energy, downtime, all of it.

Lisa Saunders

Yeah, and don’t be afraid to ask questions. A good audit should leave you with more clarity, not more confusion. And if you’re not sure where to start, reach out to Kaishan or your local distributor. They’ll walk you through it. Alright, that’s a wrap for today. Jason, always a pleasure.

Jason Reed

You too, Lisa. And thanks to everyone for tuning in. Remember, getting your pressure “just right” isn’t just a nice-to-have—it’s the key to keeping your tools, your people, and your bottom line happy. We’ll catch you next time on The Big Dog Podcast. Take care, Lisa.

Lisa Saunders

See you next time, Jason. And thanks to everyone listening—don’t forget to subscribe, and we’ll be back with more no-nonsense air system talk soon. Bye!