ROI – Worth Looking at the Details

ROI or Return On Investment is a way to gauge the productivity or profit/loss from money spent on an investment. In business, companies will use this information to determine if a project or investment is worth the risk, ultimately leading to a net profit gain as the end result.

Don’t waste your money

In my own personal experience, my wife and I were considering buying into a timeshare vacation property a few years ago. To enter into the agreement, the company required a $ 22,000 “buy-in” (financed of course) and a recurring cost of approximately $60/month for the next 22 years. This would have afforded us 124 “points” for nightly stays on our planned vacation. Their timeshare rentals are tiered into different room types – Studio, 1 bedroom, 2 bedroom or a 3 bedroom villas – with each room type costing a certain amount of points. For us to maximize the length of our stay, we would have to select the studio room which would have given 6 nights at a total of the 124 points.

We have visited this popular vacation destination several times so we know what the average cost is to spend a week on property and purchase theme park tickets for our stay. When we booked on our own, we spent on average a little less than $ 3,000 for 7 days which included our room each night and 6 day park passes per person.

The timeshare rental cost was just for the nightly stay, it didn’t include any park tickets, food or other recreations. On average, the cost for 6 days worth of park passes per adult is close to $ 450.00 and per child it was around $ 400.00. Considering there are 2 adults and 1 child (at the time) we had to pay an additional cost of $ 1,300.00.

So if we joined the timeshare and stayed for 1 week once a year, it was going to cost us approximately $ 3,020.00 ($ 1,720.00 (timeshare cost) + $ 1,300.00 in tickets). In this case, it was actually going to cost us MORE in the long run than if we booked a yearly vacation on our own (< $3,000), leading to a negative ROI. (not to mention, I really didn’t want to commit to the same vacation for the next 22 years!).

When discussing replacement compressed air blowoff solutions with a customer, many times they look at the purchase price of the device and question if it’s worth it for them to make a change. If you follow along with our blog, you will notice that over the last few months we have submitted several different entries relating to this topic, like replacing drilled pipe with our 12″ Super Air Knife resulting in a 47 day ROI or where a customer replaced 4 open copper tubes with our 1110SS Nano Super Air Nozzle and recurring their expenses in just 38 days. In these instances, we show the calculations in regards to the true cost of ownership and how quickly you can recover capital funds when considering the whole scope of the project.

At EXAIR, we are committed to providing Intelligent Compressed Air® Products that reduce compressed air consumption leading to a more efficient process, as well as increasing operator safety. If you are considering an EXAIR solution for your current process but have questions about price or performance, contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Little things add up image courtesy of Nic McPhee via creative commons license

The Case For The EXAIR Super Air Wipe

If you’ve ever used an air gun to blow something off, you’re familiar with the cleaning ability of compressed air.  If you can get the whole object blown off from where you’re standing, there really is no substitute…but what if you need to get to the other side…or sides?

Even if your product is not on fire, you probably wouldn’t want to “limbo” under it with an air gun…

This is where the EXAIR Super Air Wipe comes in…they allow you to blow a continuous, uniform 360° air stream, all around your product.  Consider their benefits:

*Sizes: the Super Air Wipe’s compact ring design means it won’t take up a lot of room; you just need a few inches, in any direction, to install one.  We stock them in eleven sizes, from 11″, all the way down to our brand-new 3/8″ diameter.

*Durability:  All EXAIR Super Air Wipes are assembled with stainless steel shims and hardware.  Models up to 4″ come with a rugged, stainless steel wire braided hose, connecting the two halves for compressed air supply.

The aluminum Super Air Wipe is available in 11 sizes; the stainless steel Super Air Wipe comes in 5 sizes…all from stock.

*Ease of installation:  Smaller sizes can be supported by the compressed air supply line, if a pipe is used and threaded into the connector hose’s 1/4 NPT port.  Larger sizes can likewise be adequately supported with pipe to both halves. All models have a bolt circle of 1/4″-20 tapped holes for more permanent and rigid mounting.  The split ring design is another key feature:

Simply open the two halves, and clamp them around your product…no threading!

*Corrosion resistance: Depending on the environment in which the Super Air Wipe will be installed, we offer them with aluminum (3/8″ – 11″ sizes) or stainless steel (3/8″ – 4″ sizes) bodies.

*Temperature rating: Aluminum Super Air Wipes are good to 400°F (204°C) and stainless steel models are good to 800°F (427°C.)

*Range of operation: We install a 0.002″ thick shim in all stock Super Air Wipes; this is suitable for a wide range of typical industrial/commercial blow off applications…a Pressure Regulator can then be used to “dial in” the air flow precisely to meet specific needs.  If a job calls for higher force & flow, additional 0.002″ shims can be installed.  Shim Sets come with the Super Air Wipe Kits, or individual shims can be ordered separately.

*Performance: Before the Super Air Wipe, a ring of nozzles was commonly used.  In fact, they still are, but we’re trying to fix that, at every opportunity we come across.  Problem with those is, it’s hard to get an even air flow all around, which leads to inconsistent blow off.  They can also be loud & inefficient, as we’ve found in numerous Efficiency Lab tests and Case Studies, like this one…

These wasteful and loud modular plastic tube blow offs…
…were replaced with EXAIR Super Air Wipes. 24 such replacements netted the customer an annual compressed air cost savings of over $13,000.00.

…and this one…

Implementing a Super Air Wipe salvaged a $30,000 job for this customer. Click on the picture to read all about it in our Case Study Library (registration required.)

Do you have a challenging blow off application that you need help with?  Call us to find out how an EXAIR Super Air Wipe (or another one of our Intelligent Compressed Air Products) can be a simple, quick & easy solution.

Adjustable Air Amplifier Keeps Sensor Cool

Our distributor in China has a customer who visited the United States, while their customer was in the US they saw an EXAIR product installed and wanted to replicate the setup in China. He saw the EXAIR label and reached out to our distributor for help in identifying the part. Taking a quick measurement of the inlet side of the Adjustable Air Amplifier led us to discern it was a Model 6041 1-1/4” Adjustable Air Amplifier.

adjustable air amplifier sensor cooling
EXAIR Model 6041

The product was installed on a baghouse monitoring system. The sensor is used to detect minor leaks within the dust collection system before the leaks create a major problem. The environment in which the sensor was installed results in temperatures that are just above the normal operating temperatures during warmer months and can result in erroneous readings. When this occurs, production is shutdown to prevent a failure of the dust collection system while the filters can be inspected. By installing the Adjustable Air Amplifier to provide a large volume of air and a low level of compressed air consumption, the temperature is able to be maintained within typical operating range for the sensor. This alleviates the need for unnecessary shutdowns (or unnecessary filter replacement), while ensuring that the working environment remains dust-free.

EXAIR’s Adjustable Air Amplifiers are available in both Stainless Steel and Aluminum from sizes ranging from ¾”-4” on the air outlet. The outlet can be ducted as seen in this application, or it can be used as-is. The air gap of the Adjustable Air Amplifier is infinitely adjustable, allowing you to regulate both the air consumption and outlet flow from a “breeze” to a “blast”. In addition to the standard Adjustable Air Amplifiers, we also have a Model 121021 High Temperature Air Amplifier available that is capable of withstanding temperatures as high as 700°F.

Air Amplifiers can be used in a variety of different applications. Not only can they be used in applications requiring cooling, but the air entrainment properties of the amplifier can be used to exhaust smoke as discussed in this application at a foundry. An Adjustable Amplifier can also be used for drying or cleaning parts as well as for conveying light materials.

Regardless of the application, EXAIR has a suitably sized Air Amplifier to fit your needs. If you need an efficient and reliable way to vent, cool, clean, or dry parts give us a call. An Application Engineer would be happy to take a look at your application and provide the best recommendation.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

What is a GEN4 Ion Air Cannon?

Quite simply the GEN4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier that has static reduction capabilities and as its name implies it amplifies the supply air up to 25 times!

This highly engineered product is very effective at cleaning product and reducing static at distances of up to 15′ away.

GEN4 IAC

The GEN4 Ion Air Cannon comes in a handy stand/mounting unit for easy installation in a wide variety of applications. It can be mounted to machine frames, mounted out of the way from a process, or placed on a bench top.

GEN4 IAC Dimensions

The GEN4 Super Ion Air Cannon can work with as little as 10 PSI supply pressure.

GEN4 IAC Performance

The GEN4 Ion Air Cannon is used in many applications such as bottling, manufacturing of solar panels and preparing new automobile car bodies to be painted – to name a few. Wherever static reduction and/or cleaning is required the Ion Air Cannon can contribute.

It is offered in a kit that can include the 7960 power supply, pressure regulator for fine adjustments, filter/separator to keep the air clean and dry and a shim set for gross adjustments or just the GEN4 Ion Air Cannon and the 7960 power supply.  Of course all components are also available individually.

If you would like to discuss reducing static and/or cleaning materials, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer

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IP Codes for Electrical Enclosures – What do they Mean?

The IP Code, otherwise known as ‘Ingress Protection’, ratings are defined in the international standard EN 60529 (or European IEC 60529.) Similar to NEMA ratings by the National Electrical Manufacturers Association, the IP ratings are used define the level of sealing effectiveness of enclosures against penetration from foreign matter and water/moisture.  The ratings for an enclosure are determined by actual testing.

The IP number is composed of the letters ‘IP’, two numbers and possibly one or two letters.  The first number refers to the protection level against solids, and the second number to the liquid protection level. The higher the  number, the greater the protection level. The optional letter codes relate to protection of persons against access to hazards within the cabinet, and any other special notice.

Below tables show the possible protection ratings and the description-

IP Table

Example – IP54 – IP – Code Letters, 1st Numeral is 5, 2nd Numeral is 4

An enclosure with an IP rating of this designation, IP54 –

  • 5 – Equipment within enclosure is protected from ingress dust of a limited quantity, such that no interference of performance is caused
  • 4 – Equipment within enclosure should have no harmful effects due to water splashed against the enclosure from any angle

Here at EXAIR we work with IP ratings everyday.  The Cabinet Cooler System line of products are made to keep electrical enclosures cool inside, while maintaining the integrity of the enclosure IP Code rating.

If you would like to talk about IP or NEMA ratings and the Cabinet Cooler Systems or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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3 Ways Static Electricity is Generated

EXAIR published a whitepaper, Basics of Static Electricity, explaining what causes static electricity, how it is generated, and steps to eliminate it. Download it now by clicking the link, and begin to eliminate the static problems on your plant or process.

In this blog, I would like to expand on the subject about how static can be generated.  On a molecular scale, the outer electrons that are orbiting the nucleus can be “stripped” and redistributed from one atom to another.  This will cause an electrical charge imbalance called static.  An additional electron will create negatively charged static while atoms losing an electron will create a positively charged static.  With non-conductive materials like plastic, paper, rubber, glass, etc, the electrons cannot move back to the original atom. There are three common methods of static generation that will cause this phenomenon to occur.  I will explain each one in brief detail below:

  1. Contact – Whenever objects hit each other, electrons can be passed to or received from the surface of another object. The number of electrons being transferred is based on the type of triboelectric material.  But, with plastic bottles or trays bumping into each other on conveyor belts, static is being generated.

    Contact
  2. Detachment – when one material is being separated from another material by peeling, electrons may not able to return back to the original molecule. Adhesive tape and protective films are prevalent in generating static charges by detachment because of the larger surface areas.  As an example; when the backing material is being removed from labels, the static will cause the labels to be misaligned.

    Detachment
  3. Frictional – This is one of the most common reasons for generating large static forces. It is caused by two non-conductive surfaces being rubbed together.  The amount of force being applied to the material as it slides back and forth will create higher static charges.   It is definitely noticed when you rub a balloon on your hair.  The more times that you rub the balloon against your hair, the stronger the static forces, allowing the balloon to “stick” to the wall.  It is also noticed as sheets of material are stacked or running over rollers.

    Friction

Static tends to propagate.  The more contact, detachment, and friction that occurs; the higher the static charges.  Even when the static is removed from the surface, static charges can still regenerate by the mechanisms above.  So, controlling the static can be determined by the treatment process as well as the location.

Another variable that affects the static generation is humidity.  Most process problems are noticed during the winter seasons as the ambient air is drier.  With a lower relative humidity, the development of static is enhanced; making it easier to produce static as well as creating a higher static force.  We always refer to winter as static season.

Production problems with static can occur like dirty surfaces, tearing, alignment, jamming and shock to personnel.  EXAIR has a number of Static Eliminators to remove these process snags and down time that will cost your company money.  You can contact an Application Engineer at EXAIR to discuss any static issues that are being generated.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Setting Goals, Achieving Results

The other day I was talking with my co-worker Russ Bowman about my oldest son’s recent string of success at school (okay I was bragging). I was telling him that the other night we were going over some of his schoolwork to get him ready for a science quiz he had the next day and how I was a little concerned because he was having some trouble retaining the information.

I spent an hour or so going over things with my son when I decided he was about as prepared as he was going to be for the test. When I picked him up the next day after work, the conversation went something like this:

Me: “So tell me dude, how’d you do on your science test today?”
Son: “I think I did OK dad, wasn’t too bad.”
Me: cringing a little… “Too bad huh? Well when do you find out your score?”
Son: “Next week sometime, BUT I did find out that I scored a 100 on my spelling test, for the TWENTIETH time in a row!”
Me: “Spelling test, you didn’t tell me about the spelling test??? You really got a 100 for the 20th consecutive time?”
Son: “Yup, so what do I get?”
Me: “What do you get? Sounds like you get an A+!!!”

Good job buddy!

 

When I was telling Russ this part of the story and sort of reliving the moment, it dawned on me (with a little help from Russ)….. you know what, getting a perfect score on a test, TWENTY times in a row is an awesome accomplishment for a 9 year old, maybe he does deserve something special for that. So I guess I’ll be heading to the sporting goods store in the very near future.

See, I don’t really have to worry about my son’s schoolwork because he takes it on himself to do well. In fact, he’s usually more upset with himself if he brings home anything less than an A. In 1st grade, he made what his school calls the “Administrator’s List” for elementary school students who maintain an A/B average and have great attendance. Last year in 2nd grade, he set a goal for himself to make the “Pastor’s List” which is the highest honor the school awards for students with a straight A average for the entire year and he made it happen! This year, he hopes to do it again and the way things are going, I think he’ll be just fine.

Here at EXAIR, our goal is to not only provide award-winning Intelligent Compressed Air Products® but also the best customer service in the industry. Whether it be by phone, email or our online chat, we make it easy for you to get in contact with a qualified representative to help provide the best solution for your needs. In addition, our cataloged products are in stock, ready to ship, and for the 22nd year in a row, we have maintained an on-time shipment record of 99.9%!

Whether you’re looking to upgrade an existing blowoff in order to lower noise or air consumption or you’d like to talk to an application engineer about solving a specific process problem, contact our team and let us get to work for you.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Big Thumbs Up image courtesy of Charles LeBlanc via creative commons