Episode 62: Measuring Compressed Air the Right Way: KPIs by Industry

Jason Reed

Alright, welcome back to The Big Dog Podcast. I’m Jason Reed.

Lisa Saunders

And I’m Lisa Saunders. Today we’re talking about something that sounds kinda boring on paper but absolutely decides whether your line runs smooth or blows up your budget: what you measure in your compressed air system.

Jason Reed

Yeah, everyone knows the “usual suspects” on a compressor: pressure, flow, maybe kilowatts if you’re paying attention to the power bill. But that’s just the basics. That’s like knowing your car’s got gas and the engine turns over. It doesn’t tell you if you’re about to fail emissions or shred the transmission.

Lisa Saunders

Exactly. The tricky part is that a cement plant, a semiconductor fab and a hospital can all run 110 PSI on the header and 500 horsepower in the room… but what really matters to each one is totally different: product quality, patient safety, contamination risk, uptime, that kind of thing.

Jason Reed

And that’s where industry‑specific KPIs come in. Everyone’s got their big five goals—efficiency, cost, reliability, maintenance, longevity. But underneath that, you’ve got different air “recipes,” depending on your world: how clean it has to be, how dry, how stable the pressure is.

Lisa Saunders

Let’s anchor this on cleanliness standards for a second. You’ve got ISO 8573‑1, which basically defines how much oil, moisture and particles you’re allowed to have in your compressed air at different classes. Then on top of that, you’ve got regulators. So, FDA and USDA expectations for food and beverage, healthcare rules for medical air, and so on.

Jason Reed

Right. And those standards drive actual numbers. So when we talk KPIs, we’re not just saying, “Eh, clean air is good.” We’re saying, “Oil content below this PPM, moisture at this dew point, particle content under this milligram per cubic meter.”

Lisa Saunders

Let’s do a quick “verbal table” so people can map this in their head. I’ll toss out the industry, you say what they care about most. Sound good?

Jason Reed

Let’s do it.

Lisa Saunders

Electronics.

Jason Reed

Electronics lives and dies on clean, dry, consistent air. So: super low oil content—around or below 1 PPM, very low moisture, down around a ‑40°F dew point, tight particle control and stable pressure swings, like within a couple PSI, for all the robotics and pick‑and‑place gear.

Lisa Saunders

Food and beverage.

Jason Reed

Big one there is compliance: FDA, USDA, plus ISO 8573. Especially where the air touches the product—direct contact and indirect contact. They’re chasing very low oil—generally below 0.1 PPM, sometimes as tight as 0.01—really dry air, colder dew point than electronics, and controlled particles so you’re not blowing junk into the food or the packaging.

Lisa Saunders

Healthcare.

Jason Reed

Hospitals need sterile, reliable air. The KPIs look a lot like electronics—low oil, low moisture, low particles and steady pressure—but the “why” is way more serious: you’re powering surgical tools and feeding air into respiratory systems. So sterility and constant quality monitoring are huge.

Lisa Saunders

Semiconductor.

Jason Reed

That’s the extreme case. They want ultra‑clean, sometimes what people call Class 0 air—so oil content pushed down toward 0.01 PPM, moisture way down around a ‑70°F dew point, and almost no particles. On top of that they track temperature tightly, microbial load, total hydrocarbons, and even do ISO 14644 cleanroom testing.

Lisa Saunders

Alright, now the heavy hitters. Automotive.

Jason Reed

Automotive’s dealing with dirt, dust and heat. They use air everywhere—weld shops, molding, robots, paint lines. They typically want Class 1 or 2 levels for oil and particles, so you don’t mess up paint and finishes, and decent moisture control so you don’t get corrosion or paint defects like fisheyes.

Lisa Saunders

Cement plants.

Jason Reed

Cement is dust city. The main KPI is particle content—keeping it under a few milligrams per cubic meter—and making sure your inlet and system filters are actually doing their job. They also watch pressure stability because every conveyor and air slide in that plant depends on solid, steady air.

Lisa Saunders

And last but not least, steel mills and metalworking.

Jason Reed

Steel mills care about temperature and contamination in a really hostile environment. It’s hot, there’s particulate everywhere. They focus on particle content staying within a limit—around that 5 mg/m³ range—controlling oil so it doesn’t get into processes, and making sure variable speed and variable‑frequency drives are happy with the quality of air feeding everything.

Lisa Saunders

So if you zoom out, every plant might say, “We monitor pressure and flow.” But the smart ones also pick a few KPIs that tie directly to their risks: food safety, wafer yield, paint quality, uptime in a dusty mill. That’s really what this episode’s about—matching what you measure to what can hurt you most.

Jason Reed

Yeah, and not overbuilding or underbuilding the system ‘cause you copied a spec from the wrong industry. In the next chapter we’ll dig into the cleanliness‑critical folks—electronics, food, healthcare, semiconductor—and what “good” actually looks like in numbers.

Lisa Saunders

Let’s start with electronics. Where does compressed air show up there, and what goes wrong if the air’s not right?

Jason Reed

Electronics uses air for assembly, cleaning and testing. Think pick‑and‑place robots, tiny valves, blow‑offs to clear boards. If that air isn’t clean, you can literally blow oil or particles onto a circuit board. That can cause shorts, corrosion later on, or just plain defects that kill yield.

Lisa Saunders

And they’re also touchy about humidity, right?

Jason Reed

Yeah. Moisture is the enemy. You want low humidity so you don’t corrode traces or create paths for current where it shouldn’t go. That’s why you see targets like: oil content below 1 PPM, moisture at about a ‑40°F dew point, particles under about 0.1 mg per cubic meter and system pressure that only swings maybe 2 PSI. That’s “good” for a lot of electronics lines.

Lisa Saunders

So if you’re a maintenance lead in electronics, your dashboard is basically: “Are we staying under those limits? And is pressure rock‑steady so the robots don’t freak out?”

Jason Reed

Exactly. It doesn’t have to be fancy; it just has to be tight.

Lisa Saunders

Alright, shift to food and beverage. I always like how they split it into direct contact, indirect contact and ambient contact. Direct is mixers, ovens, fillers—air literally touching the product. Indirect is stuff like form‑fill‑seal and cartoners, where there’s packaging in between. And ambient is just the plant air that eventually goes into the compressor.

Jason Reed

And that ambient air can be nasty—organic particles, diesel fumes, water vapor. The compressor concentrates all of that. So you need a strategy: filters, dryers, and checks to make sure your air meets FDA, USDA and whatever ISO 8573 class you’re targeting.

Lisa Saunders

What would “good” KPIs look like here?

Jason Reed

You’re usually talking oil content below 0.1 PPM, and some applications push it to 0.01. Moisture even drier than electronics—around a ‑50°F dew point—to avoid bacterial growth. And particle content under about 1 mg/m³. If you hit that, you’ve lowered your risk of contamination, recalls and ugly conversations with auditors.

Lisa Saunders

Plus, you sleep a lot better knowing you’re not literally spraying oil mist into salad dressing.

Jason Reed

Yeah, no one wants “extra virgin compressor oil” on the label.

Lisa Saunders

Okay, let’s talk healthcare. This one’s pretty sobering. You’ve got compressed air running surgical tools, feeding ventilators, supporting patients who literally can’t breathe without it.

Jason Reed

Yeah, here the key issues are sterility, reliability and constant quality control. You’re looking at similar numbers to electronics: oil content under about 0.1 PPM, moisture around that ‑40°F dew point, particles under 0.1 mg/m³, and again pressure swings inside about 2 PSI. But the stakes are different—this isn’t product scrap, it’s patient safety.

Lisa Saunders

So for a hospital engineer, the KPI list might look short—oil, moisture, particles, pressure—but each one’s non‑negotiable. And you’re verifying it regularly, not just trusting that a dryer light is green.

Jason Reed

Exactly.

Lisa Saunders

Now, semiconductors. This is like cleanliness on hard mode.

Jason Reed

Semicon fabs use compressed air for everything: precision cleaning, handling wafers, controlling the environment, doing etching and deposition, drying, cooling, even helping with wastewater treatment and nitrogen generation. And a single speck of dust can ruin a wafer.

Lisa Saunders

So it’s not just “clean air,” it’s ultra‑clean.

Jason Reed

Right. You’re talking extremely low oil—targeting around 0.01 PPM—very dry air around that ‑70°F dew point, particle content under 0.01 mg/m³. Then you pile on extra KPIs: air temperature, microbial contamination levels, total hydrocarbons, and sometimes cleanroom testing based on ISO 14644.

Lisa Saunders

And that all ties back to yield. If the air’s off, you might not notice right away, but your good‑die count on a lot tanks.

Jason Reed

Yep. That’s why they tend to over‑instrument. They’d rather catch a drift in dew point or a spike in particles long before it shows up as scrap silicon.

Lisa Saunders

So to wrap this piece up: in cleanliness‑critical industries, “what good looks like” is pretty aggressive. Oil down in that 0.01 to 1 PPM band depending on the segment, dew points from ‑40°F down to ‑70°F, tight particle limits and really stable pressure. If you’re in those markets and you’re not measuring those, you’re kinda flying blind.

Jason Reed

And on the flip side, if you’re in a heavy, dusty plant, you might not need all that. Which is where we’re headed next—what matters when your world is heat, dust and big iron.

Lisa Saunders

Alright, let’s talk about the folks who are not trying to run a cleanroom. Automotive plants, cement, steel mills, general metalworking. What’s different about how they should think about KPIs?

Jason Reed

In those plants, the air is feeding welders, grinders, robots, pneumatics, conveyors, blast air, cooling systems. The big enemies are dirt, dust, heat and downtime. So instead of chasing “lab‑grade” purity, you focus on: particle content, oil carryover, filter performance and pressure stability.

Lisa Saunders

Let’s start with automotive.

Jason Reed

Automotive has a weird mix—it’s dirty and hot in the weld and metal shops, but the paint and finishing lines need pretty clean, consistent air. They’re usually aiming for something like ISO Class 1 or 2 for oil and particles so they don’t ruin paint or powder coat, and Class 2 or 3 for moisture so they avoid corrosion and fisheyes.

Lisa Saunders

So KPIs might be: oil down around 0.01 PPM, particle content under about 0.1 to 0.5 mg/m³, moisture around a ‑40°F dew point, plus pressure not bouncing all over the place when the robots all move at once.

Jason Reed

Yeah, that’s a solid target list.

Lisa Saunders

Alright, cement plants. Totally different vibe—dust everywhere.

Jason Reed

Yeah, for cement, your number one KPI is particles. You’re trying to keep particle content under about 5 mg/m³, and you’re constantly watching filter health. So you’ll track the pressure drop across inlet filters—if the differential jumps too high, that filter’s loading up and your compressor is working harder than it should.

Lisa Saunders

And because they’re running pneumatic conveying and air slides, pressure stability matters a lot too. If header pressure sags, flow drops and suddenly your material handling gets unreliable.

Jason Reed

Exactly.

Lisa Saunders

Now steel mills and metalworking.

Jason Reed

Steel mills are brutal environments—high temperature, particles, oil mist, the works. Compressed air’s doing a ton: blast air for combustion, controlling flows in smelting and casting, powering pneumatics on rolling mills, cooling systems, tools, conveying, even air separation and dust collection.

Lisa Saunders

So the KPIs?

Jason Reed

You’re looking at particle content capped around that 5 mg/m³ level, keeping oil and other contaminants under whatever your process can tolerate so you don’t mess with alloy chemistry or foul valves and actuators. Then you monitor intake and discharge temperatures to avoid overheating, and you make sure your variable speed and variable‑frequency drives are happy—clean, dry enough air so the equipment that depends on them isn’t constantly tripping or failing.

Lisa Saunders

And those plants might not chase a ‑70°F dew point or Class 0 oil, because they don’t need to. But they absolutely do care if hot, dirty air is killing tools and causing unplanned stops.

Jason Reed

Right. You want “fit‑for‑purpose” purity, not bragging rights purity.

Lisa Saunders

So let’s land this with a simple playbook people can actually use.

Jason Reed

Yeah, here’s how I’d do it. Step one: identify your critical risks. In your plant, what’s the worst outcome tied to compressed air? Is it product contamination? Paint defects? Scrap steel? Conveyor outages? Safety?

Lisa Saunders

Step two: pick three to five KPIs that line up with those risks. You’ve got a basic menu: oil content, moisture or dew point, particle content, system pressure stability, filter pressure differential, temperature… and if you’re in those ultra‑clean or medical worlds, you might add microbiological counts or total hydrocarbons.

Jason Reed

Step three: set targets based on your industry. So if you’re electronics, maybe oil below 1 PPM, ‑40°F dew point, low particles and tight pressure. Food: push oil lower—0.1 PPM or better—and dew point colder, like ‑50°F, plus particle control. Semiconductor: go as clean and cold as you need, with those extra tests. Automotive: aim for that Class 1–2 level on oil and particles and keep moisture under control. Cement and steel: watch mg/m³ particle limits, filter ΔP, temperature and pressure swings.

Lisa Saunders

And then step four: actually build a measurement and testing plan. Decide how often you’re checking each KPI, what instruments or services you’re using, and who owns the data. Otherwise it’s just numbers on a spec sheet no one ever looks at.

Jason Reed

Yeah, don’t guess and don’t overengineer. Measure the stuff that matters for your products and your people.

Lisa Saunders

Alright, we’re gonna leave it there. If you’re listening and thinking, “I have no idea if we’re measuring the right things,” that’s a good sign it’s time to revisit your KPIs.

Jason Reed

Jason here, thanks for hanging out with us.

Lisa Saunders

And I’m Lisa. This has been The Big Dog Podcast. We’ll catch you next time with more real‑world compressed air talk.