Atomization is a word that can be seen throughout the industry in rinsing, coating, painting, lubricating, and cooling applications. The act of atomization is simple, we often refer to it when looking at liquids and… More
EXAIR has continued to build on a large catalog of Intelligent Compressed Air Products. In catalog 27 we introduced our Atomizing Nozzles ! I’m happy to announce we have added a new line of FULLSTREAM LIQUID ATOMIZING NOZZLES! , they do not use compressed air. The current Full stream nozzles available are our FullStream Cone Liquid Atomizing Nozzles with a 1/4 NPT port.
EXAIR’s FullStream Cone Nozzles, have a full cone spray pattern, are among the most common type of spray nozzles. Full cone spray nozzles are applied to solve cooling, cleaning, washing, rinsing and dust suppression applications throughout industry. Their design is vaneless, which creates wide open internal features to resist clogging and can work well with liquids containing particulate. They produce a uniform distribution in a full cone round pattern. Their right-angle design is compact and operates up to 250 PSIG liquid pressure. They are commonly used with liquids like water, rinse aids or detergents but are also effective with chemicals, pesticides and herbicides. Adjustment of the liquid flow rate is done by varying liquid pressure. FL1010SS @ 2.36 GPH & 60 PSI
Bellow you will see a video of the FullStream Cone Liquid Atomizing Nozzle, FL1010SS, 2.36 GPH @ 60 PSI.
Bellow you will see the Dimensions and Performance of the FullStream Cone Liquid Atomizing Nozzles!
If you are in the need for a Liquid Nozzle to assist in your facility, please reach out! We have a team of application engineers waiting from 8AM – 5PM EST to help you size and fit a product to your specific application!
Throughout industrial environments, there are often manual cleaning or blow-off applications that are performed with compressed air. These operations vary in frequency, intensity, and how critical to the operation they may be.
When it comes to OSHA standards and comfort of operators, many of the solutions found in manufacturing do not meet the standards and are dangerous to operators.
This is where EXAIR steps in and focuses on the end application while coupling a high performing engineered solution with an ergonomic and safe handheld safety air gun. In other words, EXAIR safety air guns are safe, easy to use, and typically reduce compressed air consumption. Currently, we offer four types of handheld safety air guns.
This is my personal favorite in our current lineup of safety air guns. The compact size fits comfortably in the hands of operators. The multi-finger trigger with patented VariBlast function is easily controlled for extended periods of time. The VariBlast Compact Safety Air Gun also has two compressed air inlets. This gives the ability to plumb compressed air into the bottom 1/4″ FNPT port or the top 1/4″ FNPT which a safe way to run air hoses for virtually any work station. The 1/8″ NPT outlet permits enough airflow to operate up to our High Power 1″ Flat Super Air Nozzle all the way down to our Atto Super Air Nozzle. The patented design also delivers variable flow from any of the nozzles attached to operate anywhere from a gentle breeze up to a forceful blast.
This safety air gun is the next step up in size and options as far as force and flow of compressed air go. The four-finger trigger and integrated hook design make this safety air gun ideal for industrial environments where a little more force is needed from the air to blowoff products. The Soft Grip Safety Air Gun offers a 1/4″ NPT female thread inlet on the bottom and is available with up to an 1106 1/2″ Large Super Air Nozzle on the discharge. This will deliver up to 60 SCFM of compressed air and provide 3.3 lbs of force from 12″ away. The Soft Grip Safety Air Guns are also available with up to a 72″ extension and a chip shield.
The Heavy Duty Safety Air Gun is even more robust than the Soft Grip Safety Air Gun and showcases a 3/8″ NPT female inlet to provide enough airflow to operate up to our model 1106 Large Super Air Nozzle as well to provide 60 SCFM of airflow and provide 3.3 lbs of force. Extensions are available in lengths up to 72″ with the addition of the chip shield.
The final Safety Air Gun offered is the Super Blast Safety Air Guns which are offered in four different NPT sizes. Ranging from 3/8″ NPT up to 1-1/4″ NPT and flows and forces from 56 SCFM providing 3.2 lbs of force up to 400 SCFM giving off 23 lbs of force. These are available with an optional 3′ or 6′ extension to provide a robust blast for the heaviest cleaning or blowoff operation.
No matter the application, or amount of debris, EXAIR Safety Air Guns have an option that will fit the need while providing a safe and efficient solution. If you would like to discuss these further, please contact us.
Over the years, EXAIR has come across many different types of blow-off devices. We have seen copper tubes, pipes with crushed ends, fittings with holes drilled into them, and modular flex lines. For compressed air use, these are very dangerous and very inefficient.
A plastic machining center was looking for a better way to blow compressed air. They were using modular flex lines, similar to Loc-line, which are mainly designed for spraying coolant. They had 14 blow-off lines in their plant that were about 18” (457mm) long and operated 8 hours a day at 40 PSIG (2.8 bar). They liked the positioning feature of the flex line, but they could tell by the loud noises that they were wasting compressed air. So, they contacted EXAIR.
When EXAIR started to manufacture compressed air products in 1983, we created a culture in making high quality products that are safe, effective, and very efficient. With our Super Air Nozzles, we engineered a way to entrain the ambient air to add mass to the air stream to use less compressed air with a strong force. This is done by the Venturi method. We create a high velocity which will make a low pressure at the exit. The surrounding air is drawn into the compressed air stream increasing efficiency. We also engineered fins to support OSHA compliance in noise levels and dead-end pressure. So, if your skin comes in contact with an EXAIR nozzle, the end will not be able to be blocked and allow air to penetrate the skin membrane; even above 30 PSIG (2 bar). I went over the cost savings and safety solutions that EXAIR’s products could give.
Since the modular flex lines had a ¼” (6mm) opening, I recommended the model 1100 Super Air Nozzle with a Stay Set Hose. This recommendation is from experience with these types of blow-off devices. The Stay Set Hoses will give them that possibility of manually adjusting and re-adjusting the Super Air Nozzles. The hoses have a “memory” function and will not creep or droop until you physically move it. They work well to direct air flows at specific target areas like the flex lines above. For the company above, I recommended the model 1100-9218 which is a model 1100 Super Air Nozzle with an 18” (457mm) long Stay Set Hose. It was easy to remove the flex line and replace it with a safer and more efficient product
Now, let’s look at the savings. The Super Air Nozzle with the 18” Stay Set Hose cost $92.00 each. The flex line is generally around $10.00 each. But this is not the total cost of ownership. As an efficiency comparison, the model 1100 Super Air Nozzle will only use 8 SCFM (227 SLPM) of compressed air at 40 PSIG (2.8 bar); and, the noise level is reduced to 70 dBA for each nozzle. At 40 PSIG (2.8 bar), the flex line had a noise level of 97 dBA and an air usage of 19 SCFM (538 SLPM).
For the annual savings and the payback period, I will look at the electrical cost. (Since the Super Air Nozzle is using less compressed air, the maintenance and wear on your air compressor is reduced.)
- The air savings is calculated from the difference in air usage; 19 SCFM for flex line – 8 SCFM for Super Air Nozzle = 11 SCFM savings per blow-off device.
- With 14 flex lines, the total compressed air savings will be 11 SCFM * 14 = 154 SCFM.
- To get into the cost, an air compressor can produce 5.36 SCFM/KW of electricity at a cost of $0.10/KWh. For an annual savings, we have the figures from the information above; 8 hours/day * 250 days * 154 SCFM * $0.10/KWh * 1KW/5.36 SCFM = $5,746.27/year.
- For a payback period, the model 1100-9218 has a price of $92.00 each, or $1,288.00 for 14 systems. The flex lines were $10.00 each, or $140.00 total. The payback period will be ($1,288 – $140) / ($5,746.27/year) * (12 months/year) = 2.4 months. Wow, what a savings!
Not all blow off devices are the same. With the customer above, they were able to cut their noise levels, remove the dead-end pressure concerns, and save $5,746.27 a year in compressed air. If your company decides to select an unconventional way to blow off parts without contacting EXAIR, there can be many hidden pitfalls; especially with safety. Besides, if you can save your company thousands of dollars per year as well, why go with a non-standard nozzle? If you are using compressed air for blowing, cooling, cleaning or moving material; you should contact an Application Engineer at EXAIR. What do you have to lose?
“I have a Cabinet Cooler installed on my panel but it isn’t getting the temperature down cold enough. Can you quote me for a duplicate system to install on this panel?” This was a recent inquiry from a customer regarding an electrical enclosure that they had installed in their plant. The Cabinet Cooler was producing cold air, but not enough to keep the cabinet at their desired temperature. It would seem logical that they need additional capacity, right? While that could be the case, in this instance it most definitely was not.
When we get questions like this, we first want to take a closer look at the current installation. The cooling capacity for each system is published in our catalog. BUT, in order to rate a cooling capacity for any type of cooling system, some assumptions must be made. All Cabinet Coolers are specified with 70°F compressed air fed to the Cabinet Cooler at a pressure of 100 PSIG. In addition, each cooler has a specified volume of air that it must utilize in order to produce that rated cooling capacity. If any one of those parameters change, so does the overall cooling power.
In this particular case, the customer had installed a non-EXAIR pressure regulator just upstream of the cooler. Upon looking at the specifications for this regulator, it was found that the overall volume of air it can deliver was just 10% of the overall volume needed to produce the rated 1700 Btu/hr. They didn’t need another Cabinet Cooler System, they just needed to remove that restriction! Upon learning that it needed 100 PSIG, they removed the regulator and supplied full line pressure. No more heat alarms for that shift!
Rather than purchasing and installing an unnecessary system, they were able to get back up and running just by removing the problem upstream. At EXAIR, we want to make sure that you’re getting the most out of our products. Just because you call and inquire about a new purchase doesn’t necessarily mean that you need it. We’re here to help you determine if something is afoul with the current setup and make sure you have all of the knowledge necessary to rectify it.
We’re right in the middle of summer, and boy is it hot out there. If you have panels that are overheating and creating problems for you in your processes, give us a call. With Cabinet Cooler Systems ready to ship same day from stock (with properly sized regulators) you can have it fixed by tomorrow.