Award Winning Compressed Air Nozzle Saves Hundreds of Dollars Annually

awards2013_1126_400wide

 

EXAIR’s 1 Inch Flat Super Air Nozzle won the Gold Award for Compressed Air from Plant Engineering in 2014. We won the award for the immense savings that our customers reap by using this nozzle to replace open blow offs. While saving compressed air, we also reduce noise level and comply with an OSHA regulation 192.242(b).  Do not leave that blow off open. It is costing you everyday in dollars; it may cost you more in OSHA fines later, and it will cost your employees hearing later.

A 1/4″ copper tube can use 33 SCFM at 80 PSIG of inlet pressure. This homemade blow off will use 1,980 standard cubic feet per hour. Typical industrial compressed air cost $0.25 per 1,000 standard cubic feet.  That 1/4 copper tube is costing you $0.50 every hour to run. Each year, one 1/4″ copper tube costs $2,970*.

The 1 inch Flat Super Air Nozzle, model 1126, uses 10.5 SCFM or 22.5 SCFM less than 1/4″ Copper tube.  Saving your company 22.5 SCFM, is the same as saving $0.34 every hour or $2,025 every year.*  Saving 22.5 SCFM also, means that your compressor system doesn’t have to work as hard.  A 5 HP compressor will put out 20 SCFM, so replacing one 1/4″ Copper Tube with a model 1126 will save you from upgrading compressor system as your company expands.

Regardless of the $2,025 you just saved by replacing the homemade blow offs with engineered nozzle, it is also an industry best practice because it can lower the noise exposure for personnel and prevent any harm from dead end pressure.  OSHA standard 29 CFR – 1910.95(a) requires that if an employee is exposed to greater than 100 dBA for 2 hours, he or she needs to wear hearing protection.  A 1/4″ copper tube will easily exceed 100 dBA.  The model 1126 will lower the noise level to 77 decibel, 13 dBA lower than the OSHA requirements for an 8 hour day.

Finally, the 1″ Flat Super Air Nozzle cannot be dead ended, which protects your employees from serious injury. In the event, that a compressed air orifice is blocked with no means of escape, air may enter the bloodstream from an open cut or wound in the skin. Compressed air must be kept below 30 PSIG to eliminate this danger when using an open pipe, tube or many commercial air nozzles. With EXAIR nozzles, pressure to the nozzle  can remain at line pressure and produce the maximum velocity and force for a successful application.

*Assuming 24 hours a day and 250 working days

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Adapting To The Situation At Hand

Earlier this week I received a call from a customer who had an issue in his facility with the hand held blow guns the operators were using.   The units he had were simply too loud and he was trying to get below the 85 dBA threshold for hearing protection.  Not to mention they were using a large volume of compressed air.

I discussed the application with the customer only to discover they are blowing dry aluminum chips off a table and need a three foot extension so the operators can easily reach all extents.   The nozzles they had on their existing blow guns were essentially a cross drilled “safety nozzle”.  The customer was using the same model air gun throughout his facility at a total of 33 machining centers.   Each unit had a gun with a 3′ extension and a cross drilled nozzle like tip.

After discussing the amount of chips and what they were using I recommended he utilize a newer style adapter we have that would appear to work on his existing gun with the existing extension.  This means, rather than having to replace the entire air gun, extension pipe, and nozzle, he was able to purchase a simple adapter along with our model 1100 Super Air Nozzle and retrofit his entire facility.  This cut the budget needed by more than half of other solutions he was looking into from other companies.   Picture of the nozzle and adapter are below.

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This was just another adapter for EXAIR but it was the right adapter for the customers existing product.  So if you have an existing blow off and you don’t want to replace the entire blow off device but you want to try and upgrade your system, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Video Blog: Changing Shims in Flat Super Air Nozzles

A brief video explaining just a few of the benefits to utilizing the EXAIR Flat Super Air Nozzles and how to change the shims which change the force and volume of flow out of the nozzle. Our shims and the adjustable air gap mean you can increase or decrease the volume of air flow and force without adjusting the inlet air pressure.

 

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

How can you protect people that don’t protect themselves?

My sister-in-law and my nephews are traveling from Columbus to Cincinnati for a visit this weekend. My nephews are 18 months and 3 years old, and they will find any sharp, fragile, or flammable object within walking, crawling or climbing distance. Of course they don’t consider these things dangerous. All they see are fun new toys. Yesterday, I battened down the hatches for the nephew hurricane that will be barreling down Interstate 71 this weekend, and there were more dangerous or scary items in the house that the nephews will want to use than I could hide.

At EXAIR, we strive to provide products that intelligently use compressed air, but everyday we have customers who are using compressed air in unsafe manner. We try to educate many of our customers and the industry as whole of the dangers and that can be associated with compressed air. The chief concern is that compressed air may cause an embolism by forcing air into the bloodstream through a break in the skin or body opening. Because of this risk, OSHA has laid down several rules for using compressed air for cleaning purposes inside the work place. To quote the OSHA Instruction STD 1-13.1, “The requirements for dynamic flow are such that in the case when dead ending occurs a static pressure at the main orifice shall not exceed 30 psi. This requirement is necessary in order to prevent a back pressure buildup in case the nozzle is obstructed or dead ended.

An open pipe used for cleaning violates this rule. Yet everyday I speak to a customer who are using open pipes to remove chips, dust or water from parts. If a employees hand is trapped against the open tube, serious injury will result. EXAIR’s Super Air Nozzles are designed with multiple openings and fins to protect those openings, so that air always has a path to escape.

 

Nozzle Lineup

 

The other safety concern with an open pipe is the noise level.  Open pipes can produce noise levels over 100 dBA which violates OSHA’s standard for maximum Allowable Noise Exposure for even 2 hours per day.  EXAIR Super Air Nozzles will reduce noise levels to create a safer more productive work environment.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

 

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