The Best Company Policy Is Right Here At EXAIR

All companies have policies. Some have a LOT. Others may not have enough. Some emphasize documenting every single action. Others write down the basics, and rely on “unwritten mutual understandings” for the rest…

We don't call it "yelling;" we call it "stuff you should already know."

We don’t call it “yelling;” we call it “stuff you should already know.”

At EXAIR, we have one core policy: to be easy to do business with. This has served the company well for thirty one years now, and I don’t expect it to be supplanted with anything else, anytime soon. Now, it may seem vague or ambiguous, but we’re quite specific, and diligent, in our methods of adhering to this one core policy:

Easy to find technical information: We offer complete specifications, performance data, dimensions, and application information for any EXAIR compressed air product on our website, and in our catalog. If you have specific questions, a team of the most knowledgeable and experienced Application Engineers in the business are standing by.

Easy to contact technical support: You can reach an Application Engineer immediately by phone or Live Chat. Emails to techelp@exair.com are also given prompt attention. We have a number of tools at our disposal, including a comprehensive test facility that we call the Efficiency Lab…if you have an operational question that we haven’t answered yet, we’ll find the answer in short order.

Easy to get products: If it’s got a part # in our catalog, it’s in stock, and available for same day shipment. Exceptions are some of our longer Air Knife products, which may take one day to ship. We can even manufacture custom length Air Knives, and ship them in only three days. Just so you know, we’re finishing up our 19th consecutive year with a 99.9% on-time shipment record.

Easy to solve applications: This is where the rubber hits the road, once we’ve made it easy to select and obtain your EXAIR product. Those same Application Engineers are ready to assist with any questions you may have about installation, operation, “tips and tricks,” etc. We’ve got an Application Database (registration required for access) that details over 1,000 successful uses of our products. Odds are, one of them is close enough to your situation to help shed some light.

Easy to solve applications, part 2: If, for any reason, the EXAIR product you buy doesn’t work out for you, we offer a 30 Day Unconditional Guarantee on all catalog products. Whether you want to get the next larger or next smaller product, a different one, or go another direction altogether, you’re not stuck with your first purchase…we’ll arrange return for full credit.

Easy to help us help the next person…and yourself: We’re keenly interested in knowing how our products work in specific applications. If you’ve put an EXAIR product to the test, and found that it’s saving you time or money, cutting your air consumption or noise levels, increasing production or safety, or any other quantifiable benefit, you may qualify for participation in a Case Study. Not only will that allow us to better apply our products, we’ve got something for you if you provide a case study for EXAIR.

If you’ve got an application that an EXAIR Intelligent Compressed Air Product may be the solution to, give me a call and find out how easy we can make it work for you.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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Max the Brown Tabby and Burt the Grey Kitten: Cat Argument 3 photo courtesy of Found Animals FoundationCreative Commons License.

Mini Cooler Provides Sewing Needle Cooling

I recently worked with a surf casting bag manufacturer who was experiencing needle breaks during their sewing operation. (The term surf casting refers to surf fishing from the beach, typically in saltwater.)

The bags, made to hold tackle and gear, are manufactured out of a sail cloth material and are double stitched for added strength. During the operation, the sewing needles would begin to heat up, weaken and break, resulting in damaged product. The customer was considering using a Vortex Tube to blow cold air across the needle and while the Vortex Tube would work well in this application, I recommended using our Mini Cooler. The Mini Cooler is engineered to provide a focused stream of 20°F cold air (based on 70°F supply) while utilizing only 8 SCFM @ 100 PSIG. The Model # 3808 Mini Cooler System includes a swivel magnet base and single point hose kit, allowing for easy mounting and delivery of the cold air direct to the tool. Another advantage is that the Mini Cooler offers a shielded and muffled hot tube, which makes it better for operations where operators may come into contact with the tube.   The perfect solution for a needle cooling application due to the fact it can easily be positioned and always puts out the 20°F air!

Mini Spot Cooler

Provides a focused stream of 20°F cold air with no moving parts.

EXAIR provides a wide variety of spot cooling products including Vortex Tubes, Adjustable Spot Cooler, Mini Cooler and our Cold Gun Systems. With help selecting the best products for your application, please call us at 1-800-903-9247.

 

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Regulators and Filters for Compressed Air

I would like to dive into the realm of filters and regulators. Majority of EXAIR products use compressed air to coat, conserve, cool, convey or clean. So, to keep the product running efficiently, we need to supply them with clean, dry, pressurized air. We offer a line of filter separators, oil removal filters, and regulators that can supply enough pressure and flow to keep the EXAIR products performing for a very long time. If we look at each individual item, we can see how they can play an important part in your compressed air system.

Regulators are used to control the amount of air pressure being supplied to your EXAIR products. This is important if you are trying to control the flow, force, and/or conveyance rate. One issue with regulators is “droop”. Droop is the amount of pressure drop when you flow through a regulator. If you set the pressure of a regulator with no flow, to let’s say 80 psig (5.5 barg). Once you start flowing, you will see the downstream pressure fall. This is dependent on the size of the regulator and the valve inside. This is very important because if you need 80 psig (5.5 barg) downstream of the regulator feeding an EXAIR product and the droop brings it to 30 psig (2 barg), you will not have enough flow for your EXAIR product, losing performance. EXAIR recommends a specific regulator for each of our products. We tested our products with the recommended regulators to make sure that you are able to get the best performance. If you do use another manufacturer’s regulator, make sure you are able to flow the correct amount of air at the pressure you need. Not all ¼” regulators flow the same.

Pressure Regulator

Pressure Regulator

Filter separators are used to remove liquid condensate and contamination from the compressed air stream. They have a 5 micron filter and work very well if you get a slug of water or oil into your compressed air system. They use mechanical separation to remove the large particles of dirt and water from the air stream. Most facilities have some type of compressed air dryer in their system. This will dry the compressed air. But, if a system failure occurs, then water, oil, and dirt are pushed into the compressed air lines and perhaps into your EXAIR products. Even if you have good quality air, it is important to keep your products protected. An ounce of prevention ….

Oil Removal Filter

Oil Removal Filter

 

The oil removal filters are used to keep the compressed air even cleaner yet. They work great at removing very small particles of dirt and oil. Without an oil removal filter, dirt particles and oil particles can collect in “dead” zones within the compressed air lines. Over time, a tacky glob forms. As it grows, it can break off and get into the air stream affecting pneumatic devices. The oil removal filter will be able to help eliminate the long term effects in your compressed air system. As a note, oil removal filters are not great for bulk separation. If you have a system with lots of water, you will need a filter separator in front of the oil removal filter to optimize the filtration. With the oil removal filters, the media is a barrier to collect the small particles of dirt and oil. If a slug of water or oil tries to go through, it will block a portion of the element off until it is forced through. This will increase the velocity and pressure drop of the element. With the high velocity, as the slug makes its way through the media, it can spray, re-entraining the liquid particles.

Now that we went through our pneumatic products, how do we use them together to get the best supply of compressed air? With both types of filters, we always want them to be upstream of the regulator. This is because the velocity is lower at higher pressures. Lower velocities mean smaller pressure drops which is good in filtration. If we can analyze the compressed air systems, I would like to categorize it into a good and premium quality. To supply a good quality of compressed air, you can have the compressed air run through the filter separator then a regulator. To produce the premium quality of compressed air, you can have your compressed air run through the filter separator, the oil removal filter, and then the regulator. With clean quality air, your EXAIR products will provide you with effective, long-lasting performance without maintenance downtime.

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

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

 

Video Blog: What Can Air Wipes Do For You

Below is a short video showing the cleaning power of a Standard Air Wipe. EXAIR has a variety of sizes from 1/2″ to 11″, and the air wipes are available in aluminum or stainless steel. Air Wipes are often used in the manufacturing processes for pipe, tubes, extruded profiles, wire and cable.

For help with your Air Wipe application, please do not hesitate to contact an application engineer at 1-800-903-9247.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

 

EXAIR Ion Bar Provides Unique Solution In Clean Room

Statically charged hopper

Statically charged plastic caps in a clean room hopper would not flow properly from the hopper into the next process. The problem was solved with EXAIR Ion Bars.

One of the well known truths in the industrial world is that lower temperatures increase the potential for static.  Another truth is that static problems wreak havoc on industrial processes.

Sometimes the process disturbance repels a label or a printing onto a material, sometimes the static causes shock hazards, and sometimes the problem is with material flow.  In the photo above, their problem was the latter of those three.

The problem for the end user was the clinging of material, preventing proper conveyance into the machine on the other side of the hopper that we can’t see.  But, looking closely at the reflection in the glass and noting the attire of this employee, we can see that this is a clean room application.

In discussing options with the end user, we determined that using an air assisted solution, such as a Super Ion Air Knife or Ion Air Cannon, posed a risk of taking any existing dust airborne without adding suitable dust collection.  Given that the problem was localized to the hopper, and that adding dust collection would increase the complexity of the solution, we sought to remove the static without air.

This left us with the tried-and-true solution of static removal without air – an Ion Bar.  The Ion Bar can eliminate a 5kV static charge in 0.30 seconds at a distance of 50mm (2″).  In this application that decay rate was more than adequate and installation of two bars across the top of the hopper “raining” ions down onto the caps was the final choice of the end user.  To allow for adequate treatment of all caps, the personnel using the machine intermittently “mix” the caps, allowing static eliminating ions to contact more of the material.

This application was a great example of how an EXAIR solution can solve a problem to increase machine throughput.  If you have an application with a similar need, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Professor Penurious, Mystery Solver!

ZOINKS! What have Professor Penurious and the gang gotten into this time? Enjoy viewing this video – we sure do enjoy making them…And recognizing that some day the Oscar committee will be calling.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Find us on the Web
Follow me on Twitter 
Like us on Facebook

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