I have a 50litre 2hp SIP compressor which has a leak in the regulator area - I undid the joints and resealed using ptfe tape but accidently overtighted and cracked the union
What is the best way to join unions to minimise leakage - is it ptfe or another jointing compound?
You could try plumbing loctite. Expensive, though.
Generally, if you're screwing into a cast female housing (as opposed to machined steel or brass) a dry fit - meaning no tape - is recommended. Friction/interference is supposed to do the trick.