That’s a direct quote that everyone at EXAIR hears at our regularly scheduled safety training meetings. While our machine tool operators & assembly technicians spend a lot more time “up close and personal” with devices… More
Measuring and Adding Sounds
My colleague, Russ Bowman, wrote a blog about “Sound Power vs Sound Pressure vs Sound Pressure Level”. He discussed the logarithmic equations around sound. I will be discussing what happens when you have more than one sound source, as often heard within manufacturing plants. Sounds can be added together to determine the overall sound level that you hear. This is very important when it comes to minimizing hearing loss.
In looking at a single source of sound, sound pressure is created by the loudness of a noise. The units are measured in Pascals. The lowest pressure perceived by human hearing is 0.00002 Pa, and we can use this value as a reference point. From sound pressures, we can arrive at a sound pressure level which is measured in decibel, dB. This correlation between sound pressures and sound pressure levels are calculated by Equation 1:
L = 20 * Log10 (P / Pref)
L – Sound Pressure Level, dB
P – Sound pressure, Pa
Pref – reference sound pressure, 0.00002 Pa
As an example, the sound pressure from a passenger car as heard from the roadside is 0.1 Pa. With Equation 1, we can get the following decibel level:
L = 20 * Log10 (0.1Pa/0.00002Pa) = 74 dB
Because human ears are sensitive to different frequencies, the sound pressure levels can be modified, or weighted, to indicate an effective loudness level for humans. This adjustment is done in two different ways; A-weighting and C-weighting. The C-weighting is for very loud noises with high peaks or sharp impacts like gunfire. The A-weighting is the most used value as the sound pressure levels are adjusted by the frequency level. For higher and lower frequencies, the change in the sound value is much greater than the mid-level frequencies that are within our hearing range. Sound measurements for safety are measured on an A-weighted scale. OSHA created a chart in the standard 29CFR-1910.95(a). It shows the noise levels over exposure times for an operator. To use the OSHA chart accurately, the total noise level in dBA should be calculated.
To determine the total sound level, we can add all the sound pressure levels together by Equation 2:
Equation 2:
Where L1, L2… represents the sound pressure level in dBA for each sound source.
As an example, a manufacturing plant had an operator using a machine that had four copper tubes to blow off a cutting operation (reference photo below).
The decibel level for a copper tube was measured at 98 dBA. The total amount of sound that the operator was exposed to was determined by Equation 2 with four values.
L = 10 * log10 (109.8 + 109.8 + 109.8 + 109.8)
L = 104 dBA
In looking at the OSHA chart above, the operator would only be allowed to operate the machine only a little over one hour without hearing protection. In this same example, we replaced the copper tubes with an EXAIR Super Air Nozzle, model 1100SS. The noise level for each nozzle is 74 dBA at 80 PSIG (5.5 bar). By replacing all four copper tubes with Super Air Nozzles, Equation 2 becomes:
L = 10 * log10 (107.4 + 107.4+ 107.4 + 107.4)
L = 80 dBA
The total sound level is now in accordance with OSHA regulations for the operator to work all 8 hours at the machine without hearing protection.
A commonly used acronym for hearing safety is NIHL, or Noise Induced Hearing Loss. To keep your operators safe and reduce NIHL, it is important to measure the total sound level in that area. As a protocol in safety, it is a requirement to use engineering standards before purchasing personal protective equipment or PPE. For the customer above, they followed that protocol with our Super Air Nozzles. If you need to reduce noise levels in your facility, EXAIR offers a large line of blow-off products that can meet the safety requirements. You can contact an Application Engineer for more information.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
How the EXAIR Chip Trapper Transforms Coolant Maintenance
In today’s manufacturing environment, efficiency isn’t just about cycle times; it’s about reducing waste, extending fluid life, and minimizing downtime. One of the most overlooked areas of optimization is coolant maintenance. That’s where the EXAIR Chip Trapper System comes in. Designed for simplicity and performance, the Chip Trapper offers a smarter way to remove chips, swarf, and sludge from contaminated liquids—without the headaches of traditional systems.
The Problem with Dirty Coolant
If you’re running CNC machines, lathes, mills, or parts washers, you already know the pain:
- Coolant becomes contaminated with chips and fines
- Bacterial growth leads to foul odors
- Pumps clog and maintenance increases.
- Fluid replacement costs add up quickly.
In many shops, coolant is replaced far more often than necessary—simply because there’s no efficient way to clean it.
What Is the EXAIR Chip Trapper?
The EXAIR Chip Trapper System is a compressed air-powered vacuum system designed to separate solids from liquids quickly and efficiently.
It works by:
- Vacuuming contaminated coolant into a drum
- Capturing chips and debris in a reusable filter bag
- Returning clean liquid back to the machine
This simple but effective process allows you to reuse coolant instead of disposing of it.
See It in Action
Key Features That Set It Apart
1. No Moving Parts = No Downtime
Unlike electric pumps, the Chip Trapper uses compressed air—meaning no motors to clog or wear out.
2. Reusable Filtration System
The filter bag captures solids while allowing clean coolant to pass through, reducing waste and operating costs.
3. Fast Operation
Systems can fill a 55-gallon drum in minutes, dramatically reducing cleanup time.
4. Complete, Ready-to-Use System
Available in 30, 55, or 110-gallon configurations, each unit comes with a drum and all necessary components.
Real-World Applications
The Chip Trapper is ideal for:
- CNC machines
- Lathes and mills
- Parts washers
- Sumps and tanks
- Grinding operations
It’s especially valuable in shops where coolant contamination is frequent and costly.
ROI: Where It Pays Off
The biggest advantage of the Chip Trapper is cost savings. By extending coolant life, shops can:
- Reduce fluid replacement costs
- Minimize disposal fees
- Cut maintenance time
- Improve machine uptime
In some cases, coolant life can be extended several times over with regular use.
The EXAIR Chip Trapper System isn’t just a cleanup tool—it’s a productivity upgrade. By turning dirty coolant into reusable fluid in minutes, it helps manufacturers cut costs, reduce waste, and keep machines running at peak performance.
If you’re still dumping coolant instead of reclaiming it, it might be time to rethink your process. Give me a call and let’s talk about the application!
| Jordan Shouse Application Engineer E: JordanShouse@exair.com O: (513) 671‑3322 F: (513) 671‑3363 A: 11510 Goldcoast Dr Cincinnati OH 45249 www.exair.com Find time on my calendar by scheduling a meeting here. |
Getting to Know the ATEX EasySwitch
EXAIR has a new addition to our Industrial Housekeeping product line, the ATEX EasySwitch Wet-Dry Vacuum System. This system will give all the convenience of our traditional EasySwitch, but suitable for use in ATEX rated zones. Below is a brief video highlighting the product’s grounding continuity.
If you have questions about the ATEX EasySwitch, or anything regarding EXAIR and our products, please do not hesitate to reach out.
Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk
The Power of Precision: Why EXAIR’s Adjustable E-Vac is a Game Changer
When designing a vacuum system, the “one-size-fits-all” approach rarely works. EXAIR offers two primary types of single-stage vacuum generators: the In-Line E-Vac and the Adjustable E-Vac. While both use a venturi design to create instantaneous vacuum without moving parts, choosing between them depends on how much control and “forgiveness” your application requires.
The primary difference lies in versatility and internal geometry. In-Line E-Vacs are compact, cylindrical units designed for specific, unchanging tasks.
- Variants: They come in “High Vacuum” models for non-porous materials (like glass or steel) and “Low Vacuum” models for porous materials (like cardboard).
- Limitation: Once you choose a model, its performance is fixed.
Adjustable E-Vacs allow you to “dial in” the exact vacuum level and flow rate needed.
- Versatility: By loosening a locknut and turning the exhaust, you can shift the unit’s performance to handle different weights or surface porosities.
- Durability: They feature a much larger throat diameter, which allows them to pass small solids, dust, and even liquids without clogging.
The Choice: Why Go Adjustable?
The Adjustable E-Vac is the superior choice when your production line handles either variety, or potentially contains contamination. For facilities that use a robotic arm to pick and place various items from a conveyor depending on the job, you would potentially need more than one style of In-Line E-Vac. For example, if one job requires lifting heavy, non-porous plastic containers, you would need a high-vacuum, low-flow unit; whereas if the next job is handling lightweight, porous cardboard boxes, this would require a low-vaccum, high-flow unit.
By choosing the Adjustable E-Vac, you can tune for porosity: Increase the vacuum flow with a quick adjustment to overcome the “leakage” inherent in cardboard. In addition to this, if the surface is less than pristine, the larger throat diameter will have no trouble passing the dirt and debris.
If you’re ready to integrate these tools, several kits and individual units are available:
- EXAIR Adjustable E-Vac Vacuum Generator 840008: A compact 8 SCFM model, ideal for smaller pick-and-place tasks.
- EXAIR Adjustable E-Vac Vacuum Generator 840015: A mid-range 15 SCFM unit for higher flow requirements.
- EXAIR E-Vac Adjustable Vacuum Generator Deluxe Kit 842030: A complete solution including the pump, an assortment of vacuum cups, tubing, a filter separator, and a pressure regulator.
- EXAIR E-Vac Deluxe Kit 842060M: A high-capacity 62.7 SCFM kit featuring a straight-through muffler, perfect for environments with heavy particulate.
If you would like to find out more, give us a call!
Al Wooffitt
Application Engineer
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