One Air Nozzle Saves $960 per Year – How Many Nozzles Could You Use?

A cardboard manufacturing facility was using a 3/8” outside diameter (OD) open tube to blow scrap cardboard off a conveyor. This scrap cardboard would occasionally be blown inside the roller area at the end of a conveyor creating a maintenance nightmare that required hours to disassemble and remove. To prevent this from occurring they installed another 3/8″ OD open compressed air tube to divert any cardboard headed toward the conveyor roller. The 3/8″ open tubing eliminated the scrap problem, but introduced a few new ones. The open hose is extremely noisy over (100 dBA). It does not comply with OSHA standard CFR 1910.242(b), which requires that a compressed air blow off device may not be dead ended at more than 30 PSIG. The most costly problem though is a 3/8″ open tubing uses a tremendous amount of compressed air.

They were using so much air in the facility that they were draining the system pressure in their facility. Obviously, they were going to replace the open tube with EXAIR 2” Flat Super Air Nozzle. Replacing this open blow off with an intelligent compressed air product, like the HP1125 High Powered Flat Super Air Nozzle or the 1104 Super Air Nozzle, would lower the noise level below 83 dBA. Also, those nozzles use significantly less air. They decided to use the model HP1125 for its thin profile to fit into the tight location. The only question was how much air and energy cost would they save. They could have easily installed a Digital Flow Meter on the supply pipe of the open tube to measure the change in flow once the EXAIR nozzle had been installed, but they wanted to try and estimate the air usage.

Using EXAIR’s test data, we know a 3/8″ OD open tube that is 18″ long will flow 68.5 SCFM at 80 PSIG. An HP1125 2″ Flat Super Air Nozzle utilizes 37 SCFM when fed with 80 PSIG inlet pressure. By removing one 3/8″ OD tube the cardboard manufacturer saved 31.5 SCFM of compressed air. With an electrical cost of $0.08 per kWh, compressed air costs $0.25 per 1000 SCF. Saving 31.5 SCFM reduces the manufacturers electrical bill by $0.48 every hour, $3.48 for every 8 hour shift, and $960 per year (250 working days, eight hours a day). If the manufacturer runs two shifts, the savings will double. The simple return on investment for this nozzle is 130 hours! How many projects can you measure a return on investment in hours?

2 Inch Flat

EXAIR’s 2 Inch High Power Flat Super Air Nozzle, HP1125

 

EXAIR intelligent compressed air products are easy to install, safe, and efficient. By installing these products instead of using unsafe open blow offs, your company can save thousands of dollar every year with minimal investment. While saving electrical expenses, we decrease the noise level which makes your production force a nicer place to work. We also comply with OSHA’s standards. Finally, we may be able to design the blow off better to consistently produce the quality product you expect. Call EXAIR today to discuss your application.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

Back At Ya!

This may not be big news as it happens almost every month.  EXAIR is continuing to grow our product line and this time it is something we have never done before.  This new EXAIR Engineered Solution doesn’t blow debris away, instead, it all comes back towards you.   Why would you want this you ask?  What does this new-fangled contraption look like?  Both of those questions will be answered below.

To answer the first question, why would you ever want debris to come back at you?  Well, this isn’t for just blowing any part or area out, this nozzle has been designed for a special purpose – to blow out pipes, tubes, extrusions, and even some blind holes or pockets.   This is ideal when working on a piping system that you may need to clean out and don’t want to push debris further into the system.   It is a quick and easy way to clean out chips from a saw cut operation for tubing or extrusion.  The nozzle could even be used to clean out cylinders or crank shaft openings on engine blocks.

So what is the name of this new nozzle and what does it look like?

What does it look like already!

What does it look like already!

 

The EXAIR Model 1006SS - Back Blow Nozzle

The EXAIR Model 1006SS – Back Blow Nozzle

This is it, the EXAIR model 1006SS Back Blow Nozzle.   The nozzle features a 1/4″ FNPT air inlet, a 3/4″ O.D. to fit into piping, extrusion, or holes, and two flats which allow for the use of a 5/8″ wrench to install the nozzle.   The nozzle is constructed of 316 Stainless Steel, utilizes  22 SCFM when operated at 80 psig, gives off 80 dBA and is designed for use with 7/8″ to 4″ I.D. pipe, tube, or holes.

The unit will also be available on our Safety Air Guns with Chip Shields to offer cleaning excellence and protection for the operators.  Like all of the stock EXAIR products, this is available with our 30 day guarantee.   So if you are not sure whether this nozzle will work on your application, give us a call, get one in, and put it through the paces.   If the Back Blow nozzle doesn’t meet your needs, simply let us know within 30 days from the date of purchase and we will take it back and provide you full credit.

If you want to discuss this nozzle or any other compressed air application, don’t hesitate to contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Finger Face – Tsahl Levent-Levl , Creative Commons License, Some Rights Reserved

 

 

 

EXAIR Now Offers Swivel Fittings Up To 1″ NPT!

Fresh off the production floor is our newly designed 1″ NPT Swivel fitting, model 9204.  This swivel fitting, much like the rest of our swivel offering is, constructed of 303 Stainless Steel, both male and female threads, 25° of adjustment from center line which makes for a total of 50° for adjustment.

 

Model : 9204 1" NPT Swivel

Model : 9204 1″ NPT Swivel

This makes the eighth swivel fitting that has been released from EXAIR.  We now offer swivels that have M4 x 0.5mm thread up to a 1″ NPT thread.   A total of 61 different nozzles from EXAIR can be combined with the swivel fittings we offer to give adjust-ability when installing a Super Air Nozzle into a tight place or within an application that requires slight adjustments to the aiming of the nozzle.

EXAIR's Swivel Fitting Family

EXAIR’s Swivel Fitting Family

If you have any questions on which swivel fitting will best suit your application, or which of the 61 different nozzles should be installed onto a swivel for your application, let us know.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

More Power? I DO Think So…

We occasionally get calls from folks who are looking for “more power” – and it always brings that classic 1990’s sitcom “Home Improvement’s” Tim “the Tool Man” Taylor to mind. Well, not so much Tim’s “more power” mantra, but the ubiquitous response from his long-suffering sidekick, Al Borland:

Al knows it.  George Foreman knows it. Lisa knows it.  Even Tim knows it, this time.

Sometimes, they’re looking for a product to replace what they’re currently using…something they’re not getting desirable results from. Other times, they have an EXAIR product in place, and it’s just not getting the job done.

Our first response is, of course, to make sure they’re getting a sufficient supply of air to their product, no matter whether it’s ours or not. If you’re familiar at all with our blogs, you know we write about this frequently:

The Importance of Proper Compressed Air Supply Lines

Video Blog: Proper Supply Plumbing for Compressed Air Products

Improper Installation and Associated Problems

3 Common Mistakes in Your Compressed Air System

Once we’ve made sure that the product is indeed receiving appropriate air supply, we can look at adding to the flow rate and force of the air stream. We’ve made it easy to do that with a variety of blow off products by designing them with a replaceable shim.

All of our Air Knife products (Super, Standard, and Full Flow) will ship with a 0.002” thick shim installed. These will perform superbly in a wide variety of general industrial blow off applications. If this doesn’t provide the force needed for your application, we carry Shim Sets for any Air Knife that will allow you to double, triple, or even quadruple the air flow for amplified thrust. Some common examples are stubborn debris in tight spaces (like the fins of a fin-and-tube heat exchanger) or removing oil from a corrugated surface.

From left to right: Super, Standard, and Full Flow Air Knives.

 

Like the Air Knives, our Air Wipes (Super and Standard) are built with 0.002” thick shims, which can be easily replaced for additional flow and force. Like when the Air Wipe is getting all the coolant off an extruded & machined part, but some stubborn, hair-like fibers need a little more “oomph” to remove.

 

Super (left) and Standard (right) Air Wipes come in sizes from 1/2" to 11".

Super (left) and Standard (right) Air Wipes come in sizes from 1/2″ to 11″.

Yes, those were real calls I took. Yes, they had sufficient air flow. Yes, the extra shims worked like a champ.

Similar to our Air Knife products, our Flat Super Air Nozzles also incorporate a replaceable shim. In fact, you have your choice of standard Models with a 0.015” thick shim installed, or High Power Models with a 0.025” thick shim. Shim Sets with a variety of thicknesses from 0.005” to 0.030” are available for either of these.

Our Super Air Amplifiers and High Velocity Air Jets incorporate patented shims that make for the highest amplification flows available, anywhere. These are available, from stock, in Shim Sets or individually.

High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.

High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.

If you have an air blowing application that you’d like to get a little (or a lot) more out of, give us a call. Prepare for a discussion on proper air supply first (of course,) but we’ll be more than happy to help in any way that we can.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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Model 1109-PEEK Solves Customer Dilemma

1109-PEEK

1109-PEEK Nozzle used in non-marring blowoff application

In a recent application for a new installation, an end user of EXAIR products needed a way to remove defective material from a production line.  At times, the defective items would fall along a conveyor, and the end user wanted to install an effective, efficient blowoff system to address multiple points along the conveyor.  Further to the complexity of the application, the end user needed a product that would not damage the product any further, as they reworked those items to reduce total scrap rates.

Initially, we considered a series of PVDF Super Air Knives, one of which could be triggered “ON” when material was detected.  But, the material size is relatively small, leading to the installation of many, many small Super Air Knives.  This solution was viable from a performance perspective, but further review found a more economic solution.

We then considered Super Air Nozzles.  Perhaps a series of small, efficient nozzles, controlled in groups of (5) or (10), could provide the desired blowoff force.  But, what about the need to not damage the product if in contact with the blowoff device?

This is where the PEEK plastic, model 1109-PEEK, became a perfect fit.  A series of 1109-PEEK nozzles provided the necessary blow off force, consumed minimal compressed air, and provided a non-damaging, non-marring solution.  When controlled in clustered groups, the specific section of the conveyor could be cleared of the defective material, blown into bins for reworking.

These attributes of the 1109-PEEK nozzle, along with high chemical resistivity, and a high temperature range (up to 160°C / 320°F) make it a viable choice for a variety of applications.  Maybe that’s why it is currently nominated for a Plant Engineering Product of the Year Award in the Compressed Air category – Please VOTE for the Precision Air Nozzle here.

EXAIR Application Engineers are well versed in the parameters of our products and a wide range of industrial applications.  If you have a need for engineering support in your application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Go Vote For The EXAIR 1104-PEEK!

2014_exairPOYfinalistG_300px

Plant Engineering Product of the Year Awards

 

In case you missed our blog on EXAIR having 4 finalists for Product of the Year 2014 from Plant Engineering there is a link here.   Today however, I would like to focus on just one of those products, the Model 1104-PEEK, 3/8″ FNPT Peek Plastic Super Air Nozzle.

The Model 1104-PEEK Super Air Nozzle blows off solar panels during assembly inspection.

The Model 1104-PEEK Super Air Nozzle blows off solar panels during assembly inspection.

The 1104-PEEK is constructed out of PEEK Thermoplastic which is designed to be chemical resistant, non-marring, and carries a high temperature rating.  The chemical resistance of PEEK plastic will help greatly in locations such as plating operations, chemical etching or cleaning metals, painting, or glass etching.  The low friction characteristic of PEEK plastic makes it ideal when trying to blow off delicate surfaces which may be scratched by metallic blow off nozzles such as, painted surfaces, glass, plastics, or even polished metals.  The PEEK thermoplastic is rated for environments up to 320°F (160°C).  This can be ideal for paint or coating curing ovens.   This could also come in handy around the exit of a furnace where there may be caustic fumes mixed with elevated temperatures.

When you combine all of the benefits from PEEK plastic with the engineered solutions from EXAIR, you will get an efficient, safe, engineered solution to your blow off application that will work in a caustic or hot environment, yet not mar a delicate surface.

If you have an 1104-PEEK already in your application, or are using another EXAIR product, please go and vote for us in the Plant Engineering Product of the Year awards.   We greatly appreciate all who are willing to vote for any of our products and are proud to continue bringing you the best products we can offer that fit your every compressed air need.

Brian Farno
Application  Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

I Love A Good Commercial

I watch an awful lot of television. I always have. I grew up in the 1970’s, and I can STILL remember the sixth sense that my friends and I seemed to possess, regarding the imminent air time of our favorite shows. We could be engaged in the most epic Friday evening whiffle ball game EVER, but a few minutes before 8pm, we all became acutely aware that The Incredible Hulk was about to come on, followed by The Dukes Of Hazzard. Throughout the week, our games might be called on account of weather or darkness, but on Fridays, they’d be called on account of Lou Ferrigno (The Hulk) and Catherine Bach (Daisy Duke.) It’s entirely likely that this was triggered by the subtle reinforcement of having viewed a short advertisement earlier in the week, shown multiple times, just to make sure it stuck:

For the record, we didn’t watch Dallas an awful lot.  We got sent to bed right about then.  In retrospect, I’m glad.

In the present age of Digital TV and programmable DVR’s, I honestly don’t watch too many shows when they’re actually being aired. And with the fast forward function, I don’t catch too many commercials, except when (much to my wife and sons’ chagrin) I back up to see if I might be interested in. And yes, it’s usually food or vehicle-related. I’m usually in the mood for a cheeseburger, and…don’t tell her…but I may be purchasing a pickup truck very soon.

But I digress. I got to thinking about the effectiveness of commercials when I had the pleasure of discussing a blow off application with a caller recently. He was looking for a way to keep the lens of laser sensors clean…there are three sensors located inside his machine, and they are used to check & control the exact positioning of precision machined parts. As good as they are at doing so, just a little bit of coolant spray on the lens will have a pretty bad effect on their operation. When he started describing the sensor to me, I knew exactly what he was looking for, because I’d seen something just like it in a “commercial”…

These Press Releases can all be found in our Media Center.

These Press Releases can all be found in our Media Center.

OK, a Press Release, actually. Now, this is the Model HP1126SS 1” High Power 316SS Flat Super Air Nozzle, which was needed for the aggressive, high temperature environment in which this photo was taken. He didn’t need all that, so he went with the Model 1126 1” Zinc Aluminum Flat Super Air Nozzle, which has more than enough force & flow to blow off a little coolant mist, and is perfectly suitable for use around water-based solutions.

When I showed it to him, he agreed that it was exactly what he was looking for. I feel bad that I neglected to tell our Marketing folks how easy they made it for me to solve this application until now…but they totally rocked it. Thanks!

Our Application Engineers work with them to publish Press Releases, Newsletters, Case Studies, Application Database entries, and more, on a regular basis. I encourage you to check out our Media Center and Knowledge Base (registration required, but it’s free and easy) to get an idea of the full range of our abilities to solve your compressed air product applications. We can start there, and if you ever have any questions, give us a call. We’re eager to help.

Russ Bowman
Application Engineer
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