EXAIR Web Site Feature: Air Data

 compressed air

Many times when we are working with customers we’re not always using the same units of measure that they are to describe pressure, force, flow or even temperature. And so, in order to help keep us and our customers all on the same page, we have developed some useful tools within the Knowledge Base section of our web site called Air Data.

The Air Data pages include links to pressure conversions, flow conversions, force conversions and heat conversions. We also explain in detail how to calculate air consumption and the differences between the various types of metal and non-metal piping systems that can be used in industry.

Finally, we have available various tables that describe the amount of expected pressure drop that can be expected through a pipe when various input pressures and flows are considered.

Overall, there is a lot of useful information in this part of our web site to help with compressed air system design and determining requirements for various types of end use products, like ours. We encourage everyone to check it out.

Neal Raker, Application Engineer
nealraker@exair.com

Super Air Nozzles Are a Better Solution for an Application

Granular brick residue blow off 2

Earlier this morning I took a call from a production facility here in the U.S. with a specific application need.  In this facility, bricks are made via automated processes, and during one stage of production a residue remains which affects future product progression.

To combat the residue accumulation, airguns were mounted in place with the triggers zip tied and controlled by an adjacent solenoid.  Using 1/4″ NPT nozzles of unknown origin, these air guns remove the build up of small granular dirt along the edge of the bricks. An image of this setup can be seen above.

While the solution provided some relief, the compressed air use was deemed excessive and the noise level too high.  The end user in this case contacted EXAIR for a more efficient and more quiet solution.

Due to the size of the existing nozzles, and the desire of the end user to only replace the nozzle portion of the setup, our recommendation was to use model 1100 or model 1126 Super Air Nozzles.  Based on prior experience, I recommended to test each style of nozzle to determine which will provide the better result.

The customer responded in turn. “Not a problem.  We have other applications that need this same type of upgrade.  I’m sure we’ll use them both and be calling you again.”

Solving problems and upgrading existing solutions is what EXAIR products are designed to do.  If you have an application you’d like to discuss, contact an Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

There Are Trial Periods and Then There Are Trial Periods

I recently was contacted by my satellite TV provider advising me that I qualified for a free whole home HD DVR upgrade and “free” 12 month trial for premium movie channels. According to their customer service, ALL I had to do was agree to pay an additional $3/month and they could be out early next week to upgrade our system. I was a little wary because usually if it sounds too good to be true, IT IS!

parental-advisory-thumbnail

I agreed to the terms and was then transferred to the equipment / installation department to schedule the upgrade. After nearly a 30 minute wait, the representative wanted to review…… “you are getting an amazing deal, this system usually costs $399.00 but you are getting it for FREE!!!! BUT there are so many people taking advantage, we won’t have anyone available for the installation for about 2 weeks”. This was fine with me because there weren’t any issues with my current system.

We agreed on an installation date and then the “too good to be true” surprise…. “sir, all we need now is your verbal agreement to the 24 month contract of service. If you cancel the contract, the termination fee will be $20/month for the remaining months of the contract. Do we have your authorization to proceed?” What? I thought this was a FREE trial?

At EXAIR, occasionally our customers ask if we offer a demo or trial unit to test with their application. We do not want to offer product which has been loaned out on demo previously, we provide a brand new product for our Unconditional 30 day trial. With a new product trial we can make certain the product has been assembled and tested properly and you receive a top performing product. We simply ask that you place the order (credit card or purchase order) and if for ANY reason within the first 30 days after purchase, you may need to return the unit, you will receive FULL credit for the product. This also allows the time to test the unit, in your application, at your site, to ensure you are getting optimal performance with our products and desired results.

30 Day Guarantee

In addition to our Unconditional 30 Day Guarantee, we also offer our 5 Year Built to Last Warranty, for defects in workmanship and materials on all compressed air products. We offer a 1 Year Warranty on all accessories and electronic devices for manufacturer defects.

Feel free to contact an Application Engineer for assistance with your application. We look forward to providing a solution for your application.

Justin Nicholl
Application Engineer
Justinnicholl@EXAIR.com
@EXAIR_JN

 

Save The Enclosures

Who cares about overheated electrical and electronic enclosures?  Why, Professor Penurious does, of course.

We can’t quite tell if he’s begun a charity, but this is one sad group of electrical enclosures…

Russ Bowman
Application Engineer
www.exair.com
twitter.com/exair_rb
facebook.com/exair

 

Need A Lift? Use the New High Lift Reversible Drum Vac

At EXAIR we continue to develop new products to meet our customer’s needs. For example, check out Brian Farno’s blog titled “Once Again EXAIR Is First To Tackle The Impossible”, introducing our new single piece construction, Long Super Air Knives (up to 108”- In Stock!).

I would like to introduce another new product, our High Lift Reversible Drum Vac. Consuming only 43 SCFM @ 80 PSIG, this system will produce a lift of 180” H2O or 15 feet - filling a 55 gallon drum in less than 85 seconds! With 3 available sizes, 30, 55 or 110 gallon, this system is designed to quickly attach to any closed head drum. The High Lift Reversible Drum Vac can also move thicker liquids than the standard duty product.

HLRDV

You can easily convert this system to a pump, providing 30 GPM (water), with the simple turn of a knob – quickly emptying the drum.

Requiring no electricity and with a built in pressure/vacuum relief, these units are safe to operate. Considering these units have no moving parts, they are virtually maintenance free.

Visit EXAIR.com and check out our complete line of Industrial Housekeeping Products. Or for assistance with a specific application, contact one of our application engineers.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Bottling Line Can Run Efficiently by Taking a Few Simple Steps

I recently visited a local customer who bottles a liquid drink.  They do two different sizes, single serve and gallon bottles.  The main issues they were having is the gallon bottles were not dry enough after they come out of a cooling / rinse tunnel.  They currently had three different blow off devices in place outside of this cooling tunnel.  The cooling tunnel had hundreds of spray nozzles to both rinse and cool the gallons of liquid.

On the exit of the tunnel there was a blower driven air knife that was being powered by a high maintenance motor that was also sucking in non filtered air to blow the moisture off thee gallon jugs.  The blower was not producing high velocity air and the knife position could not be adjusted for maximum effectiveness due to the hard piping from the blower.

The bottles come out of the blower and go from a 60″ wide conveyor to a 24″ wide conveyor in about five feet of travel. The bottles are then funneled down even further into a single file line and then sped up and sent through two 90 degree bends to try and knock any residual water off them before going into the casing machine.

There were no other blow offs on the gallon line because they were concerned with their compressed air use.  The other two blow offs they had in place were on the single serve bottling line. On that line there were two points that had six separate clusters of a metal flat nozzle that was approximately 1″ wide and were all pointed at a different point of the cap to try and eliminate some moisture that would get trapped under the lip.

The single serve bottles would come out spaced approximately six inches apart but the nozzles were blowing continuously.  This was a very large waste of compressed air.  They could have very easily installed an EXAIR EFC on these supply lines to cut their usage by more than 50% of their current demand.   They then went past an open pipe blow off to help dry the final labeling point.   This was also on continuously which was another opportunity for air savings.

I recommended installing two Electronic Flow Control (EFC) units and replacing their existing nozzles and open pipe with the EXAIR model 1126 1″ Flat Super Air Nozzle outfitted with swivels to allow them to be positioned properly to reach under the bottle cap. Proper positioning, in many cases, increases the effectiveness of the nozzles and can get the job done with fewer nozzles installed. In this application I am confident we can get that bottle cap area blown off with only 2 nozzles.

By eliminating excessive nozzles and cycling compressed air on and off only as needed, the customer saves compressed air. I estimated it was enough compressed air to install a 24″ Deluxe Super Air Knife Kit to blow down on top of the gallon containers, which is the primary reason they asked me to visit in the first place. This will not only give them the 24″ Super Air Knife, but it will also include the crucial EFC and a filter separator to clean the compressed air and a pressure regulator to adjust the pressure down to the minimum necessary for success. All of these factors contribute to optimizing compressed air and using it effectively within anyone’s plant:

  • Eliminate open pipes and ineffective blow offs
  • Turn off compressed air whenever possible
  • Keep it clean to reduce wear and maintenance
  • Adjust the pressure to a minimum level for success

This is just one location in the entire facility where implementing the Electronic Flow Control and EXAIR engineered nozzles will help the customer to optimize their compressed air use.

If you would like to learn more or have questions on any of the EXAIR products mentioned in this blog, feel free to contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Adjustable Air Amplifier Removes Heat, Protects Thermocouple

I was working with a customer recently who had a fairly interesting application that I’d like to share with you. The customer operates a steel furnace and they have an automatic, liquid steel temperature probe that does not have sufficient time to cool down before they take another temperature measurement which should be a minimum of 5 minutes.

thermocouple

The probe consists of a 6 foot long, ¾” pipe, attached to the end of a 12 foot long beam. The beam lowers the pipe with the probe attached into the steel bath to take the temperature (see sketch below). The pipe is covered with a consumable, cardboard type of tube (pictured above) which is the thermocouple.  A contact block with wiring inside the pipe connects to the thermocouple. This contact block becomes heat damaged because the pipe does not have enough time to cool between temperature measurements.

steel temperature

The customer was originally thinking about using a Super Air Knife to cool the probe and pipe between temperature measurements. After discussing options, the customer took our advice and went with (2) of our 2” Stainless Steel Adjustable Air Amplifiers (model 6042) instead. The Air Amplifiers are able to be mounted at the “parked” position of the pipe / probe and actuated to blow down the pipe and thermocouple length-wise during this time.

The high velocity airflow was able to carry enough heat out of the assembly between temperature measurements that the contact block was no longer becoming overheated and damaged as it was before. We decided to suggest this option to the customer because the air usage for this option was less than that of a 60” long Air Knife and the Stainless Adjustable Air Amplifier has temperature rating of 400°F which was easily able to withstand the heat in the application.

Neal Raker, Application Engineer
nealraker@exair.com

 

 

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