Dual Promotions in December

In case you haven’t seen our tweets, our website or e-news; we are currently running two promotional offers.  We decided that December is a month of giving and so we better make sure our customers receive a little something extra.

The first promo…  Receive a FREE Soft Grip Safety Air Gun w/ Super Air Knife purchases.  When you decrease your air consumption by replacing that pipe with drilled holes or manifold of nozzles with a Super Air Knife, you will receive a Free model 1210 Soft Grip Safety Air Gun w/ 1100 Super Air Nozzle.  You do have to use the promotional part numbers so follow the link below in order to get to the right information pages.

atos_bSAK225x180

The second promo is based on our extremely popular Cold Gun Aircoolant System.   Now through the month of December, purchase any Cold Gun Aircoolant System with a single point cold outlet and receive a free dual point hose kit as well.  The dual point hose kit expands the area you are able to cool or is best for larger diameter tools. Once again, you do need to use the promotional part numbers so follow the link in the picture below.

CGPromoad_186x133

Both of these promotions are valid through December 31st, 2014.  If you have any questions on how you can use any of the items mentioned, feel free to give us a call.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Ordering Off The Menu, Revisited

I wrote a while back about ordering off the menu, in regard to technical data on EXAIR products. I’d like to share another example of how we can help, if you don’t find just what you’re looking for in our catalog.

I recently had the pleasure of helping a new Line Vac customer – a machinery builder – who needed a combination of properties of two different products: the stainless steel construction of the 2” NPT Threaded Line Vac, but the performance of the 2” Heavy Duty Threaded Line Vac. The Installation & Operation Guide actually gives you instructions on drilling out the generator holes for increased air flow & performance, but they didn’t want to disassemble, modify, and reassemble the units if they didn’t have to. Which was fine with us – we were able to perform these modifications in assembly, and ship them, surprisingly quickly (surprising to our “new” customer anyway…) and they were quite pleased with the results. So much so, that the modified Line Vac is now standard equipment on this new machine.

Which of these Line Vacs has higher performance?  We can't be sure without checking the generator!

Which of these Line Vacs has higher performance? We can’t be sure without checking the generator!

We get a fair number of calls about products or applications that don’t EXACTLY fit the parameters, specifications, and performance ratings of our catalog products. Some of them simply won’t work…and we’ll tell you. Other times, though, we’re able to put our Design, Production, and Application Engineering skills to the task, and hit one out of the ballpark. And we’re set up to do it better than anyone else.

If you’d like to discuss a compressed air products application that’s a little (or a lot) “off the menu,” give us a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Find us on the Web
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Full-Flow Air Knife Assists With Flour Recovery

I took a call from a customer who was looking for a way to recover residual corn flour on their chain and paddle, drag conveyor. As the paddles moved down the line, they would start accumulating flour which was leading to uneven batch runs and waste. After reviewing the application with the customer, they determined they were only needing to blow off the width of the paddles, so I recommend using our 18” stainless steel Full-Flow Air Knife.

The Full-Flow Air Knife provides a 30:1 amplification rate (entrained air to compressed air), to produce a high velocity curtain of air that travels the entire length of the knife. With a small profile of only 1” H x 1.25” W, the unit is the ideal choice where mounting space is limited. It is available in a 303SS material which was suitable for this wash-down application.

Full-Flow

The Full Flow Air Knife is available in aluminum or stainless steel construction, up to 36″ stocked lengths.

 

Due to the concern regarding dust, I recommended operating the unit at a gentle 20 PSIG, lowering the velocity to 3,000 FPM and reducing the air consumption to only 1.1 SCFM per inch. A simple pressure regulator is capable of adjusting the volume and velocity of output airflow in order to “fine tune” our knives per application. This would allow for the needed blowoff, as well as reduce the potential of the unwanted dust.

If you have a similar application or would like to discuss your process, please don’t hesitate to give us a call at 1-800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Super Air Wipe Blows Wire Clean After De-scaling Process

saw-application

We had a customer recently who processed wire rod. Part of their processing includes de-scaling and polishing the outside of the wire. Their problem was that at the out-feed of the polishing machine, they were getting a lot of carry-out of grit and scale from the wire de-scaling and polishing process.

To counter the problem of carry-out, they decided to mount model 2400 ½” diameter Super Air Wipe at the out-feed section of the machine in order to blow back all the debris and scale into the machine where it could be collected nicely by a drawer in the bottom of the machine base. Prior to installing the Super Air Wipe, the customer would have to clean up piles of debris outside the machine. Now it is all contained nicely within.

Do you have an application where you are processing a continuous, round, extruded material that needs to be cleaned, dried or blown off?  If so, the Super Air Wipe is an excellent choice to provide the full 360 degree wipe around the outside of the material.

Neal Raker, Application Engineer
nealraker@exair.com

Special Air Amplifier? Not A Problem!

This week I worked with two customers that wanted to boost their air flow with an Air Amplifier. One customer ended up going with a Special Air Amplifier. The second customer I ended up pointing to a different product line entirely. Keep reading to find out why.

The first customer needed to boost the exhaust flow through six inch duct.  The six inch duct was an open vent that allowed fumes to slowly escape from a vessel. During normal operation the vessel, was unmanned, so the fumes only need a path to escape, but could linger. The company wanted to do some maintenance work in the area while the machine was in operation. The vent met the necessary requirements for the air flow of the machinery, but left maintenance workers exposed to a variety of fumes while working in the vessel, if the unit was in operation.

The customer was interested in the model 6034 Stainless Steel Air Amplifier. With 0.002″ air gap and 80 PSIG of inlet pressure, the unit will flow 1,200 SCFM of compressed air at the outlet of the Air Amplifier, but the 6034 can be adjusted to much higher flows from there.  The Air Amplifier would easily be able to exhaust the fumes from the area to maintain a safe and comfortable working environment. The problem was mounting the 6034 Adjustable Air Amplifier. The 6034 is designed to be used in free air with the discharge side of the air amplifier connecting to a duct. The suction side of the Air Amplifier is as open as possible to entrain air, but my customer needed to connect the Air Amplifier to the outlet of the vent. We worked with the customer on designing an Air Amplifier to fit the 6″ Flange that they used to connect sections of their duct similar to the Air Amplifier pictured below.

special air amplifier

This special stainless steel flange-mount Air Amplifier was designed for exhausting hot flue gases from a furnace.

My other customer called to move the air inside a heated drying tunnel. The customer uses a process air heater to heat a large drying tunnel. Unfortunately, the air heater created hot air at the entrance of the drying tunnel. By the time the air reached the end of the drying tunnel the temperature was significantly higher at the top of the tunnel as opposed to the bottom from natural convection. To counter this effect the customer wanted to move air from the process heater half way down the tunnel and release the air. In this application, the customer wanted to duct both the inlet and the outlet of an Air Amplifier. The Air Amplifier is not well suited for ducting and you limit the amount of air that the Air Amplifier can entrain by connecting it to a duct.

For this customer, I recommended he use a Line Vac. The Line Vac typically conveys materials, but it will also move a good amount of air.  The customer was going to use heated compressed air and wanted to convey the air from the process heater to the other side of the drying tunnel. Another key benefit to the Line Vac is the discharge and suction side of the units are both the same size.  This makes it extremely easy to install for the customer and is off the shelf, ready to ship.

Two similar applications on the surface that result in different product recommendation. Not every application for an air mover is this complicated, but if you want to talk through your application EXAIR’s application engineer’s will be happy to help.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

Cabinet Coolers and Water?

I enjoy the days in Fall when you have the cool mornings, and the sunny afternoons. Have you awakened in the morning, poured yourself a hot cup of java, and looked outside your window? You notice that the grass, the leaves on the trees, and the seat of your lawn tractor are wet. The reason for this is attributed to dew point. Dew point is the temperature at which water vapor will condense and form water droplets. That same term applies in compressed air. If the dew point temperature and the air temperature are equal, then the air is 100% saturated (water vapor can start condensing to form water droplets).

Another way to get water in your compressed air system is by pressurizing it. When you take ambient air and compress it, the amount of “elbow” room for water vapor decreases. This causes the water vapor to condense and create liquid water. It would be similar to a water-soaked sponge.   As you compress it with your hands, like your compressor, the sponge will not be able to hold onto the water, and it will release the excess. Under that same hand pressure, the sponge is still fully saturated (i.e. if you continue to squeeze the sponge and dip it back into the water, it will not be able to absorb any more water). The compressed air system is the same. As soon as the air is compressed, water will start to form and fall out of the compressed air. Now you have water in your compressed air lines.

     A customer asked me about our Cabinet Cooler® system. He said that if we reduce the temperature by 54 ⁰F (30 ⁰C) in an electrical panel, will water condense onto the circuitry? Electricity and water can be a disaster but in this case we can be confident of no condensation on the circuitry. I researched this phenomenon a little further, see the details and analogy below.

NEMA 12 EXAIR Cabinet Cooler

NEMA 12 EXAIR Cabinet Cooler

Most facilities have some type of compressed air dryer in their system. This will reduce the dew point of the compressed air system. As an example, a refrigerated dryer will reduce the pressure dew point to 40 ⁰F (4.5 ⁰C). This means that liquid water will not be present in your compressed air line until the temperature is below 40 ⁰F (4.5 ⁰C). I also know that when you expand the air from 100 psig (6.9 barg) to atmospheric pressure, the air will become dryer (or the dew point will become less). Just like the example of the sponge, if you loosen your grip (going from a pressurized system to a non-pressurized system), the sponge will become “dryer” and can now absorb more water. As we combine these two concepts, we can determine if water will condense from the compressed air and become “dew” on the electrical components. If we take a typical 70 ⁰F (21 ⁰C) plant, the Cabinet Cooler® will cool the air to 16 ⁰F (-9 ⁰C). (The specification of our Cabinet Cooler® at 100 psig (6.9 barg) and 54 ⁰F (30 ⁰C) temperature drop). Let’s calculate the dew point temperature of the air exiting the Cabinet Cooler®. In looking at an elevated pressure/atmospheric pressure dew point chart, the 40 ⁰F (4.5 ⁰C) dew point of your compressed air line will drop to -6 ⁰F (-21 ⁰C) when it expands to atmospheric pressure. Thus, the temperature of the air coming out of the Cabinet Cooler® is 20 ⁰F (-7 ⁰C), and the dew point is -6 ⁰F (-21 ⁰C). So, no water will condense from the compressed air. With proper filtration, the efficiency and effectiveness of your Cabinet Cooler® will last you a long time and keep your electrical components cool and dry.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Image courtesy of Windell Oskay. Creative Comment License

Don’t Let Winter Shock You: One Danger to Quality that You Cannot Forget

Winter is coming. The humidity will drop. Electrostatic discharges will rise. We will all be shocked again, and again –  it’s a reality of manufacturing processes in the winter and can cause such a nuisance.

Static Electricity is created by materials such as paper, plastic or textiles rubbing, peeling, or sliding across a surface. Materials normally contain and equal number of positive and negative charges. As the two surfaces come into contact electrons will transfer from one material to another.  If these surfaces are not electrically grounded, they will gather a charge.  For instance, if you rub your sock across the carpeted floor before you reach out and touch your kid sister over the holidays, you may be able to shock her enough to take her eyes off of Instagram.  This is the same phenomenon that you can also see in lightning storms on a meteorological scale.

Electrostatic discharges may only be a nuisance to you and me as we climb in and out of cars, open door knobs, or touch our computers, but for a number of industries the rise in static will make producing quality products in  a timely manner significantly more difficult. Printing, packaging and slitting operations can be stopped or ruined by static. Some of these applications require a very long static eliminators between 60 and 108 inches.

Ion Bar

Two long ion bars remove static from laminated panel.

 

For wide web applications EXAIR builds Long Ion Bars up to 108″ in length. These bars can clean up printing errors caused by static in large inkjet printers.  They can eliminate static before or after a slitting operation. Also, they can eliminating static before painting or staining.  These bars will be invaluable to the paper, textile, film or plastic industry as winter continues to lower the humidity.

2014_exairPOYfinalistG_300px

Plant Engineering Product of the Year

 

The folks at Plant Engineering have nominated EXAIR Long Ion Bars for Product of the Year. If you are currently using the Long Ion Bar or another EXAIR product, please go vote for our products in the Plant Engineering Product of the Year Award.

Dave Woerner
Application Engineer
@Dave_Woerner
DaveWoerner@EXAIR.com

 

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