Full Flow Air Knife Increases Airflow By 3000%

Condensor Housing

Inside of the housing of the photo above is an EXAIR Full Flow Air Knife. The housing serves as a shield to a condenser on a specially built machine for one of the Big Three U.S. auto manufacturers. The purpose of the air knife within the housing is to supplement heat removal by passing large volumes of ambient air over the condenser, thereby helping to return the gaseous fluid to a liquid state.

When compressed air was supplied to the air knife in this photo, there was very little airflow. Knowing that there was something amiss, and that an Application Engineer could offer potential solutions, the OEM called in to EXAIR.

Immediately upon seeing the photo, the root cause of the problem was evident. There was no ambient air available for the air knife to entrain. It looks like an attempt was made to open the housing *in the bent edges at the top of the housing), but it was not enough.

Removing the housing from the machine revealed the following internal installation.

Condensor Housing Internal

With such a setup, there was no entrainment of ambient air, and the total airflow was only a fraction of what it should be. Removing the current shield and fabricating an alternate design which allows ambient airflow solved the problem in this application. Compressed air use remained low, and total airflow was increased by 3000%.

EXAIR products keep compressed air use low and performance to a maximum. For help with your application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Award Winning Compressed Air Nozzle Saves Hundreds of Dollars Annually

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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

The Value Of Free Stuff…Sometimes, It’s Actually Worth The Price

I visited my doctor recently for my annual check-up. During the exam, he lamented that a lot of his patients didn’t take the importance of preventive care seriously enough. I joked that I’m actually one of those people, but since my health care insurance covers an annual check-up at no charge to me, I do it simply because I’m a sucker for free stuff. Again, I was JOKING…I firmly believe in the importance of preventive health care, and strongly encourage you, dear reader, to do the same and get annual check-ups.

Well, I was HALF joking, anyway…I AM a sucker for free stuff. In fact, my doctor and I went on to talk about how effective free stuff (like t-shirts) was at getting consumers to sign up for new credit cards, magazine subscriptions, etc. We had a good laugh, and I kept laughing…until I got home and looked in my t-shirt drawer…

Of course, these kinds of promotions can be great advertising – that’s obviously why they’re so popular, and at EXAIR, we’re keenly aware of that. Now, you can’t wear our free stuff for everyone to see, but, in the case of our current seasonal promotion, you can get something very useful for free:

Through May 31st, we’re so intent on helping you get into Spring Cleaning mode that, with the purchase of one of our Industrial Vacuums, we’ll give you a FREE Vac-u-Gun. VACpromo_186x149 How can an efficient, quiet compressed air operated Industrial Vacuum help get your spring cleaning into full swing?  If you need help answering that question, give me a call.  They’re all in stock, and we ship same day (U.S.) with orders received by 3pm EST.

Russ Bowman
Application Engineer
Web: www.exair.com
Blog: http://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

EXAIR Receives Plant Engineering Product of the Year Awards

Every year EXAIR strives to meet our customer needs with new products. On a day to day basis we communicate with customers who voice problems for which we might or might not have a solution. When we can’t help a customer, we see that as an opportunity to grow our business and meet those customers needs. Over the last year we have released over 250 products to fill our customer’s requests. We submitted 4 of those products to Plant Engineering for voting by their readers for Product of the Year.

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The 2013 Product of the Year Awards – One silver and three gold!

All (4) products were recognized by Plant Engineering and their readers this year.

The awards received, the products and the categories were:

Gold Award – 1 Inch Flat Super Air Nozzle – Compressed Air

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Gold Award – Dual 316 Stainless Steel Cabinet Coolers – Electrical Controls

NEMA 4X Dual Steel

Gold Award – No Drip External Mix Atomizing Nozzles – Fluid Handling

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Silver Award – Heavy Duty HEPA Vac – Environmental Health

HD HEPA

Over the next month, I will talk about each product and detail their features, benefits and applications. If you need help on any application, feel free to contact us.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

 

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