EXAIR Efficiency Lab Does It Again

EXAIR Efficiency Lab

Yet another EXAIR customer has taken advantage of the EXAIR Efficiency Lab.   For those that do not know, the EXAIR Efficiency Lab is a service that EXAIR extends to our customers, to compare their current compressed air process to our engineered compressed air products.  For example, you simply send your existing nozzles to us OR an Efficiency Lab Survey and we will do our best to replicate your conditions.  Then we will cross reference your current product performance to our catalog products and see where we can help you to conserve your compressed air and benefit from an EXAIR product.

This customer was currently using a “Nozzle” in an array of 11 nozzles per line  to blow off debris from their manufacturing process.  The customer was continuously running 2 lines during production which gives a total of 22 nozzles using compressed air.  The nozzle they were using was actually a pipe nipple that had been formed into a somewhat flat shape to disperse the air a little more.  A picture of one of these nozzles is below. 

When the nozzle arrived at EXAIR we first documented what exactly it was then we started to bench mark the customers process.  At the pressure the customer was operating the nozzle was consuming 137.45 standard cubic feet per minute of compressed air.  This allowed the crimped nipple to generate 5.7 lbs. of force from twelve inches away and give off 109 dBA of noise from three feet away.  The other key part of information to this application is that the ambient temperature of the part being blown off was approximately 2,000°F and the crimped nipples were positioned within a few inches of the part.  Because of this we had to consider the temperature greatly in our recommendations. 

Once benchmarked, we then began to test our comparable products at the same operating pressure as the customers existing process, and form a recommendation for the customer.  The recommendation is not only saving them compressed air but also reducing the noise level of the operation and become OSHA compliant.  The nozzle that best fit was the model # 1113SS.  Each nozzle is able to save the customer nearly 46.5 SCFM of compressed air when it is operated just below their operating pressure of 88 PSI.  The stainless steel nozzle can withstand temperatures of 1,000°F and will also lower their sound level from 109 dBA to 96 dBA.  And though the crimped pipe was able to achieve 5.7 lbs of force the 1113SS will produce 4.5 lbs. of force from twelve inches away, more than enough to solve the customers application of removing scale from an extruded pipe.  

The key savings for this customer is the fact that when they implement the 1113SS nozzle into their system they will be saving over 1,000 SCFM of compressed air for their operation.  Using a cost of   $0.25 / 1,000 CF of compressed air, the customer saves $120.00 USD per 8 hour shift or $30,000 per year.  That is a considerable amount of savings and is simply achieved by implementing an Engineered Nozzle into one application in the facility.

If you have an existing compressed air application and want to know if there is a better way, take advantage of the EXAIR Efficiency Lab.  We’ll find the better way for you to utilize your compressed air. 

Brian Farno
Application Engineer
BrianFarno@EXAIR.com

You’ll Get Nothing and Like It!

Words suitable for a parent, not a business.

Ah yes, those six words – You’ll Get Nothing and Like It – the result of a few dinner time stand-offs in my days both as a child and a parent. You may be familiar with the situation, here is how it goes for me as a parent…

My wife willingly prepares dinner for 5, including kids with a variety of preferences. One who won’t eat anything he doesn’t like the look of, one who won’t eat anything he doesn’t like the texture of and one who will eat just about anything on her plate. The kid who eats anything on her plate may seem like a good deal but is really just an opportunity for her to act like an angel, rub it in her brother’s face and generally perpetuate an already bad situation.

So we tried a few remedies. After a short career of negotiating which resulted in compromised parental control the next natural and not-so-well-thought-out step was bribery. We bribed with desert, Wii time, TV time etc…which resulted in kids who expected a reward for every choking bite they managed to get down AND a noticeable increase in the number of foods the kids thought should qualify for a bribe. I mean when your kid expects to play video games in return for scarfin’ down that plate of chicken nuggets, you have an issue.

So then we began to ponder providing a variety of choices at each meal, catering to each child every meal, but the logistics and implementation quickly rose beyond our abilities – not to mention a clear loss for the parental team. So as it happens to many of us, those traits possessed by my parents which clearly made my youth miserable became the best solution. And though we do not shout “you’ll get nothing and like it!” – the message remains the same with the simple use of an under utilized word in the parental lexicon – NO.

  • Do I have to eat this?      No.
  • Can I have something else?     No.

It’s a beautiful thing to see what a kid will eat after only once making the choice to prove they can go to bed hungry. And over time we continue to try new meals we think will be a success and add any meal with moderate reward to our menu. The result is a broad menu of kid pleasing items, most of the time. It is a win/win.

But as a business, those six words are unacceptable. And even though our willingness, action and outcome of providing a variety of products for a medley of customers in a collection of industry are unmatched, we will still get an unsolvable application or two. And it is at this point where the process differs because we will then negotiate with the customer. This allows us to see if modifying an existing product could provide a solution.  Or we will gather more information about the application to decide if we can offer a different solution at a different point in the process. And at the very least we have listened to the customer and try to offer a potential solution even if it does not involve EXAIR at all.

We will not, however, bribe a customer – though a 30 day unconditional trial is a perk for an application we have not yet solved. And if the customer begins to expect it every time, no problem, it is a standard policy for every cataloged item.

Providing a more diverse product line to cater to each customer is the result of our ability to listen and act. For many years we have listened to what our customers need and want. After listening, we act. Our actions have produced completely new product lines of  Line Vac air operated conveyors and Air Wipes. It has also caused us to expand existing lines, Long Super Air Knives and Large Super Air Nozzles for example. And though we do not shout “you can get anything you want” – the message remains the same with the simple use of an under utilized word when a business is listening to a customer – YES.

  • Do I have an application you can help with?     Yes.
  • If I need something else, are you willing to help?     Yes.

It’s a beautiful thing to see how a customer responds to a business willing to help beyond selling their wares. And EXAIR recognizes the benefits of treating those customers  to the best of our abilities. It is a win/win.

Kirk Edwards
Application Engineer
KirkEdwards@EXAIR.com
@EXAIR_KE

Understanding Oil Filter Beta Ratios

When buying hydraulic oil filters elements, the filter industry developed standards to measure the true effectiveness of the filter. A filter that is marked or rated “10 micron” has some ability to capture particles as small as 10 micrometers. However, you do not know exactly what this means unless you also have a description of the test methods and standards used to determine the filter rating. The results from the different test methods may not be comparable as their method varies greatly.

 Two of the key standards are the filters“Micron” rating and the “Beta β” ratio. The “Micron” rating describes the normal particle size the filter removes.

What does the word micron mean? It is another term for micrometer (1 millionth of a meter).  A micrometer is a unit of linear measure in the metric system used to measure distance from one point to another. Its scientific notation is μ. Here are some objects that will give you a visual of comparative sizes:

  • Diameter of average human hair 70 microns
  • Lower limit of visibility (naked eye) 40 microns
  • White blood cells 25 microns
  • Talcum powder 10 microns
  • Red blood cells 8 microns
  • Bacteria 2 microns
  • Carbon black 0.6 microns
  • Tobacco smoke 0.5 microns

Beta ratio (b) is formulated by dividing the number of particles of a particular size in the upstream flow by the number of particles of the same size in the downstream flow:

where bx is the beta ratio for contaminant larger than x mm
Nu is the number of particles larger than x mm per unit of volume upstream
Nd is the number of particles larger than x mm per unit of volume downstream.

The beta ratio is an indicator of how well a filter controls particulate: i.e., if one out of every two particles (>x mm) in the fluid pass through the filter, the beta ratio at x mm is 2, if one out of every 200 of the particles (>x mm) pass through the filter the beta ratio is 200.
Therefore, filters with a higher beta ratio retain more particles and have higher efficiency.
Efficiency for a given particle size (Ex) can be derived directly from the beta ratio by the following equation:


Read more: http://www.lenntech.com/library/fine/beta/beta-ratio.htm#ixzz104rJzTX4

 An example would be a filter with a “β6 = 75” would be 98.67%  efficient at removing particles 6 micron and larger.  CALCULATION:   (75-1)/75 * 100 = 98.67%

Here is an efficiency tabel for your reference:

Beta ratio information can also be stated as β 5/10/20 = 2/20/75. In this example, the media tested removed

  • 50% of 5-micrometer or micron size particles
  • 95% of 10-micrometer or micron size particles
  • 98.7% of 20-micrometer or micron size particles
Beta Ratio  Efficiency

2

50%

10

 90%

20

95%

75

 98.7%

100

99%

200

 99.5%

1000

99.9%

A filter’s beta ratio also does not give any indication of its dirt-holding capacity, the total amount of contaminant that can be trapped by the filter throughout its life, nor does it account for its stability or performance over time.

Nevertheless, beta ratios are an effective way of gauging the expected performance of a filter.

references:
SAE J1858
ISO 4548-12,lube & oil
ISO16889, hydraulic or fuel
ANSI (American National Standards Institute)
NFPA (National Fluid Power Association)
Filter MAnufacturers Council

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Web: www.exair.com
Twitter: www.twitter.com/exair_jp 
Facebook: http://www.facebook.com/exair

 

LIFE > WORK

Ever have the idea for something you want to say or write about, but it’s just not fully formed yet?  I first thought about writing this blog a few weeks ago, but I just didn’t feel like I had a good handle on it.  As time has passed, events have happened that brought things into clearer focus for me.

Everyone in the working world seems to struggle to various degrees with striking the proper balance between work and life.  Whatever your “proper balance” happens to be is a highly individual determination.  In general, most people agree that work commitments get in the way of life commitments sometimes.  Trying to successfully fulfill both parts while neglecting neither is an exhausting but necessary exercise.  This week has been an epic example of this struggle for me.  Work and life commitments have made the last few days very long indeed.

Over the past few weeks, several friends and family of EXAIR team members have fallen ill with conditions that generally are not ever resolved successfully.  At times, it seems that there are not enough hopes, prayers or tears to go around to all in need.  Reminders of our universal mortality seem to come at every turn.  The latest reminder came last night.  My wife and I were at a hospice facility where her uncle peacefully passed away with his son at his side.  He was a two-time grandfather that unfortunately will miss his granddaughter’s birthday party next week.

As is often said, life is too short.  It’s too short to forget, even temporarily, about our loved ones and families while other things get in the way.  It’s too short to lose focus on the things that are really important while dealing with the mundane.

And it’s too short to ever assume that someday we’ll have the time to pursue our passion projects after we get our work finished.  “Someday” isn’t guaranteed to come.  What we don’t do today may never get done.

We all need to realize that we have choices to make in work and in life.  None of us can possibly do everything that we want or need to do at any given time.  Changing goals sometimes requires changing directions, and time is not always on our side.

With that in mind, we bid a fond farewell today to Gary Gunkel, our Marketing Manager for the past 14 years and an EXAIR team member for 22 years.  Gary hired me as an Application Engineer back in 1992 and was my first manager at EXAIR.  Gary was smart enough to recognize that “someday” isn’t guaranteed and that what you do for a living doesn’t necessarily define who you are as a person.  Gary has decided to pursue his lifelong love of music, combined with service and teaching, as music director for his church.  The change in direction and schedule will also allow him to attend to family matters that require his attention.

We had a brief gathering this morning to wish Gary our best with food, gifts, laughter and a few tears.  No amount of thanks will be enough for his contributions over the years and he will be missed.  He was a strong factor in shaping this company over the past 22 years, and for that we will be eternally grateful.  I hope to convince him to make a guest appearance from time to time.

Take some time today to think about the things that are important to you.  Give your friends and family a hug.  Enjoy their company.

And make every day count.

Bryan Peters
President
bryanpeters@exair.com

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