The Time When The Only Thing Better Than An EXAIR Product…

…was another EXAIR product. And actually, it happened twice, just today:

  • An insulation manufacturer was using an open pipe blow off to push air into a five foot wide “blanket” of their product to uniformly flatten it, and blow stray fibers out and into a vacuum system for recycling. They tried a Super Air Knife, which blew the stray fibers out just fine, but didn’t produce the flatness they desired, even with additional shims installed. They then experimented with a manifold system, using a series of Model 1104 High Force 3/8 NPT Super Air Nozzles, which provided the force required to blow the loose fibers out, and to produce the uniform material thickness. With a sound level of only 82dBA (which you won’t find ANYWHERE ELSE from a device that delivers 1.9 lbs of force,) they’ve also made the area much quieter.
Definitely try a Super Air Knife first, but if the job calls for high force, Super Air Nozzles can be easily fitted into a pipe manifold like this.

Definitely try a Super Air Knife first, but if the job calls for high force, Super Air Nozzles can be easily fitted into a pipe manifold like this.

  • A major producer of adhesive labels and specialty packaging had been using our Line Vacs extensively for scrap trim removal. They tried them on a new application where the trim was very lightweight. I’ve written before about When You Can Use An Air Amplifier, or A Line Vac, or…Either? – and this was again the case. They tried a couple of Adjustable Air Amplifiers: a Model 6044 4″ unit for the larger pieces, and a series of Model 6043 3″ units to gather in the rest, as the product traversed the production line.

Normally, we like to reserve our bragging on EXAIR products to how much better they’ll perform than the competition’s.  Which we do regularly, and we’ve got the data & experience to back it up.  But, with such a diverse product line, there are going to be situations – like these – where more than one product might fit the bill.  If this is the case, give us a call; we’re here to help you get the most out of your compressed air usage – whichever EXAIR product that may be!

Russ Bowman
Application Engineer
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Multiple Products Provide a Solution to Improve a Laminated Sign Making Process

A manufacturer that produces laminated signs contacted EXAIR for a blow off application. Being that we are experts in this area, I thought this would be a simple solution. The conversation started out about the signs that they manufacture. They are laminated sheets that have a thin aluminum film with a coating on the front and back sides. Their process was to cut stacks of these signs that he called books to specific dimensions. Here is how the conversation went in a shortened version:

Problem –

  1. I need to blow off chips from the saw process.
  2. It has to be strong enough to remove the chips that are melted into the face of the laminate.
  3. When the blade gets dull, the chips become hotter. The operator has to blow on the blade as it is cutting to reduce the amount of chips that melt into the laminated face.
  4. After the machine finishes and the books are removed, the table lifts up and disposes of the excess chips.

Solution –

  1.  Model 1122 2” Flat Super Air Nozzle to blow a wide area off the top of the signs after sawing.
Model 1122: 2

2″ Flat Super Air Nozzle

2.  Model 5330 High Power Cold Gun with dual point hose to place on the saw blade. This will extend the life of the blade and help keep the chips cool. Eliminating the melting into the face.

5330 High Power Cold Air Gun

High Power Cold Gun System

3.  Model: 110248 Super Air Knife Kit to blow the chips from the table after it is lifted.

Super Air Knife

Super Air Knife

As you can see, with a simple initial question, it became complicated rather quickly. Instead of looking at one area of the application, I was able to improve their entire process. In any manufacturing plant, scrap and downtime are the two biggest culprits in reducing profits. The scrap occurred when the faces were scratched and damaged. The downtime happened during the cleanup between book change-overs and when the saw blades were being replaced. Overall, their process improved in efficiency and speed.

Whenever you need to look at the overall process for improvement, EXAIR may have multiple solutions to offer. You can speak to an Application Engineer to see how EXAIR can increase your efficiency and reduce your scrap. You can either call 800-903-9247 or send an email to

John Ball
Application Engineer

If It Ain’t Broke…It Could Still Improve

…Don’t fix it, or so the saying goes. Sometimes, though, we have the opportunity to talk to compressed air product users who are looking to redefine the term “ain’t broke.” There are, for instance:

*People with end-use compressed air devices that came with their machines, which “ain’t broke,” but may be louder, or costing more to operate, than an engineered solution. A prime example of this is replacing an open-ended blow off with a Super Air Nozzle. We’ve got (69) distinct products in our Air Nozzles & Jets line…we’re sure to have one that’ll install quickly and easily, with immediately noticeable improvements. Improvements including a more comfortable work environment from lower noise levels and a lower air consumption which will provide your compressor relief and save air for other or future applications.

EXAIR Model 1100 Super Air Nozzle installs easily on copper lines, with a simple compression adapter.

EXAIR Model 1100 Super Air Nozzle installs easily on copper lines, with a simple compression adapter.

*Expansions to processes, or add-ons to systems. We’ve helped out more than a few customers in the automotive industry – from manufacturing to detailing – who are now able to move more vehicles through by enhancing their existing central vacuum systems with EXAIR Model 6292 Vac-u-Gun Transfer Systems. They use these guns at work stations to deliver scrap and debris into the central vacuum system, the Vac U Guns have shortened the time spent removing scrap and trim by boosting the vacuum flow at the work station.

With three systems to choose from, we've got the portable vacuum system you need.

With three systems to choose from, we’ve got the portable vacuum system you need.

*Perhaps something “ain’t broke,” but it’s also not as safe as it could be. Our E-Vac Vacuum Generators and Vacuum Cups are perfect solutions for pick-and-place applications that keep operator’s hands away from machinery, while still allowing for the safe removal of manufactured parts. Actually, though, if the particular situation is “not as safe” enough to constitute an OSHA violation, we would certainly classify that as “is broke.” Call me NOW. I can help.

EXAIR In-Line E-Vacs and Vacuum Cups...ideal for quick, easy pick-and-place systems.

EXAIR In-Line E-Vacs and Vacuum Cups…ideal for quick, easy pick-and-place systems.

*”Bucket and Ladder” material transfer methods may be described as “ain’t broke” (usually by people who aren’t carrying the buckets up the ladder) but they certainly can be time and labor intensive. EXAIR Line Vacs have been solving these applications for years. From packing peanuts to steel shot (and just about anything in between…so long as it’ll fit inside a hose from 3/8” to 6”,) we’ve got it covered. Check this out and see for yourself:

Whether or not you’d call your current situation “broke” or not, if you’re thinking about it, I bet it’s worth talking about. Give us a call.

Russ Bowman
Application Engineer
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Reduce Compressed Air Use, Maintain Effectiveness with Engineered Nozzles

I had a customer that was making steel blades. The machining operation drilled a bevel into the side every 6” (152 mm). He needed to blow off the chips from the surface. They designed a box that they indicated as a “Blow Box”. This box contained four ¼” nipples that were smashed at the end to blow onto the blade. The purpose of the blow box was to blow the chips from the surface of the blade and the machined bevel and to contain the chips. The chips would fall into a bin underneath the blow box for recycling. The design is shown below.

Blow Box Trouble

Blow Box Troubles

The chips were not completely being blown off the blade or from the inside of the bevel. He decided to contact EXAIR to see if we could help. In his design of the blow box, we discovered two issues. The open pipe was using too much compressed air causing the air pressure to drop in his system. The second problem was the orientation of the nozzles. The chips that were being blown off would settle back onto the blade as it exited. I recommended to use four of our model 1122 2” Flat Super Air Nozzles to replace the open pipe nozzles. I also suggested to have them mounted on the side of the blow box to blow across the blade.

The Flat Super Air Nozzle has a strong force that can be directed to the flat surface. With the other setup, the suspended chips could fall back onto the blade. To help remove the chips from the box, I suggested the 1 ½” Heavy Duty Line Vac model 150150. He could place the vacuum opening on the side of the blow box to capture the loose chips and transfer them into the recycle bin below. The four ¼” NPT nipples were using roughly 276 SCFM (7,815 SLPM) of compressed air. By replacing the flattened pipes with the model 1122 2” Flat Super Air Nozzle, it would save him 190 SCFM (5,380 SLPM) of compressed air. The customer was happy with a clean blade and his compressor was happy for the reduce load.

If you ever come across a situation where you need help with compressed air applications, you can always call EXAIR and speak to one of our Application Engineers.

John Ball
Application Engineer

Intelligent Compressed Air Products: Pulling In Free Air

Home of Intelligent Compressed Air Products

EXAIR is the home of Intelligent Compressed Air Products.

What is an Intelligent Compressed Air product? What makes it intelligent? Compressed air is typically a manufacturing facility’s most expensive utility. A standard cost is $0.25 per 1,000 Standard Cubic Feet (SCF) produced. Any pipe, manifold, or fitting can be modified to blow compressed air, but these homemade blow offs will be very noisy, waste a tremendous amount of compressed air and create an OSHA violation. In contrast EXAIR’s intelligent compressed air are engineered solution are quiet, use a minimal amount of compressed air and comply with OSHA safety standards.

Let’s take EXAIR Model 1100 Super Air Nozzle as an example. Connecting it to a 1/4 NPT fitting, will produce 13 ounces of force on a target when mounted twelve inches away, and use 14 SCFM of compressed air. To produce so much force using that little air, the Super Air Nozzle must be precisely designed and manufactured to maximize the entrainment of ambient air.

With the air nozzle we use compressed air to induce a primary air flow. This primary air flow is a high velocity jet of air that create low pressure area around the primary airflow entraining the ambient or free air. These air streams combine past the tip of the nozzle creating a powerful blast of air. The Super Air Nozzle can entrain air up to a ratio of 25 parts of ambient air moved for every 1 part of compressed air.  All of our Super Air Nozzle create this level of air entrainment.


EXAIR Super Air Nozzle entrains ambient air up to a 25:1 ratio

In addition to entraining a significant amount of air, the Super Air Nozzle also reduces the noise level. Most homemade nozzles are not well constructed so, the hole(s) that allow the air to escape may have sharp jagged edge which will induce noise or turbulence. Even commercial nozzles with cross drill holes create a tremendous amount of wind shear which leads to an ear splitting compressed air squeal. The smooth design of the Super Air Nozzle creates a laminar flow of air that reduces the noise of the nozzle to 74 dBA. For reference a 1/4″ open tube can easily create noise levels over 100 dBA. Using a compressed air nozzle, can greatly reduce the amount of noise in and around your shop.

Finally, EXAIR Super Air Nozzle complies with OSHA standard 29 CFR 1910.242, which requires that all nozzles that use compressed air over 30 PSIG must provide a point of relief in case the nozzle is dead ended. EXAIR Super Air Nozzle uses multiple orifices that are recessed, so that the air always has a path of escape. Many homemade nozzles do not have any provision to protect from dead ending, which means they do not comply with the OSHA standard.

EXAIR Super Air Nozzles are an important upgrade from a homemade nozzle and many times an upgrade for a commercial nozzle, because they entrain ambient air, reduce noise level, and comply with OSHA regulation.

Dave Woerner
Application Engineer

Peanut Butter And The Flat Nozzle

So, the call came in about mid-morning – an operator at a facility that fills plastic jars with peanut butter needed help with an application…

And I almost got stuck thinking about peanut butter. I like food, and peanut butter is near the top of my list. I’ve seen it successfully applied to cheeseburgers, and the peanut butter & bacon sandwich is even a breakfast staple in some of the Boy Scout groups I’ve been involved with. Crunchy or creamy, peanut butter rules.

Never underestimate the power of peanut butter...or improve the quality of any sandwich.

Never underestimate the power of peanut butter…or bacon…to improve the quality of any sandwich. And together, they’re unbeatable. Just don’t ask your cardiologist.

Now, I’m a pro, so I didn’t allow this digression to supplant the attention I was giving the caller. The application was simple enough: the nozzle feeding the jars retains a small amount of the product at the tip, which drips off when it’s good & ready, thank you very much. This is oftentimes when the jar is in motion, so this little glob falls right onto the rim of the jar, causing issues with the protective seal, and a continuing mess as this jar with peanut butter on the outside of it travels down the line.

I recommended a Model 1126SSW 316SS 1” Flat Super Air Nozzle, with Swivel Fitting. They can install this to blow precisely where the air flow can direct the last bit of peanut butter from the fill nozzle into the jar, eliminating the mess, and any chance of a faulty lid seal.


The Model 1126/1126SS 1″ Flat Super Air Nozzle is ideal for high velocity, forceful blow off applications 

If you’d like to know more about how EXAIR Intelligent Compressed Air Products might help your processes run a little smoother, feel free to give us a call.

Russ Bowman
Application Engineer
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Peanut Butter and Bacon Sandwich photo courtesy of Arnold Gatilao  Creative Commons License

1″ Flat Super Air Nozzle Is Key In This Application

I was recently working with an automation company who was looking for a way to remove reject blank keys from a 12″ conveyor. The keys are placed on the conveyor in single rows spaced roughly 1″ apart, As the keys travel down the line, occasionally there will be a key that was damaged during the stamping process and needs to be removed from the production run. We initially discussed our Super Air Knife to blow across the width of the conveyor but they wanted to focus on the various rows, providing a single blast of air to remove just single irregular keys, one at a time.

Broken Key

I recommended they use (6) of our Model # 1126 1″ Flat Super Air Nozzle and space the units 1″ apart to cover the width of the conveyor. The 1″ Flat Super Air Nozzle provides a 1″ wide, high velocity focused airflow. The unit is shipped with a .015″ shim installed, providing 9.8 ounces of force when operated at 80 PSIG. The shim can be changed to different thickness levels either opening or closing the gap, providing more or less force and flow to meet the demand of the application. They were also looking for a way to operate the units independently so the nozzle would only work when their sensor identified a reject key. For this independent control, I recommended they use a solenoid valve on each supply line, allowing them to operate the nozzles from their control system.


1″ Flat Super Air Nozzle with shims for adjustability.

To see how we can help with your automated system, please contact an application engineer @ 800-903-9247.

Justin Nicholl
Application Engineer

Broken Key image courtesy of Alex Roberts   Creative Commons License


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