Just when you thought you had optimized your compressed air system, EXAIR comes along to improve it further.
One of our customers manufactures X-Ray film. They take the film off of a roll and sheet it. The film sheets run along a vacuum belt to hold them down and hold them flat. The film rides along the belt and runs over a series of gaps in the belt. Each gap is a place where the film can be stacked in sheets.
At these gaps the customers uses air nozzles to blow on the leading edge of the sheeted film to deposit the film into the stack. Our customer, who had doubts, called to see if we could help save additional compressed air and lower the noise in the system they had fabricated. They had a total of 49 nozzles.
They were using nozzles which consumed 9 SCFM at 80 PSIG and produced 6 ounces of force on to a target 12″ from the nozzle. The decibel level of the nozzle was 81 dBA. Those number are pretty good, but lets look at what we provided for them.
Our engineered Nano Super Air Nozzle consumes 8.3 SCFM at 80 PSIG, a total air consumption savings of 34.3 SCFM (49 nozzles). It produces a higher force value of 8.1 ounces on a target 12″ away and runs at a quiet 75 dBA. All improvements of the existing system!
Just in air alone, for a 16 hour production time which runs 250 days a year we save over 8 million SCFM! And the return on investment is 209 days!
Not bad for switching out some nozzles.
In my job as an applications engineer I come across some interesting and bizarre applications for EXAIR’s products. I was recently contacted by a parks director who needed to frost up the branches of the trees in the park to effect a winter scene.
They did not have access to a snow making machine so they wanted to cover the trees with ice crystals. Hosing them down with a garden hose weighted the branches down too much and created an ice slick all around the trees.
Installing one end of a siphon tube into the suction end of a model 6092 Vac-U-Gun and the other end into a bucket of hot water, the Vac-U-Gun drew up the hot water, atomized it, and added it to the outgoing air flow. Since it was well below freezing, the hot water fog turned to fine ice crystals that easily coated the branches of the trees. The fine ice crystals glistened in the light and was the exact effect they were looking for.
This holiday season has been moving along well and been pretty smooth. I have been able to determine what gifts would be good for my sons and daughter, really without a hitch. That is until I realized my daughter is suddenly interested in clothes and earrings and other weird big kid stuff. My days of browsing the cool toy aisles are waning. So even though I had some other things in mind, I realize it is better to pay attention and act accordingly. Much is the same with customers…
Our original Line Vac product has been used to move everything from grains to plastic pellets to fish renderings. They have been on the market for more than ten years and proven to be a product line where listening to our customers has caused numerous expansions within the product line. as we sold more basic units, our customers began to ask for certain modifications.
One of the expansions we made, the Heavy Duty Line Vac, was to offer the Heavy Duty Line Vac for customers who needed to move abrasive materials which would quickly wear the aluminum or stainless steel and also provide a solution for customers who were moving exceedingly heavy materials like shot blast media or iron oxide.
One of our customers who manufacture float glass have been successful for years using our Adjustable Air Amplifiers to lay a nitrogen blanket down on the sheets of glass. Knowing of EXAIR and our product line they called to see if we could aid them in moving iron oxide. Their material weighs in at 176 pounds per cubic foot and they needed to move 75 pounds in 6 minutes, vertically 9 feet.
Since we have done testing on many different materials and distances, we were able to confidently recommend the 2″ Heavy Duty Line Vac for the application. It can move the volume they needed and resist the abrasion of the iron oxide. Just another instance where listening provided a successful win-win between our customer and EXAIR.
Now, wish me luck on the win-win for my daughter and I.
Happy Holidays to everyone.
I was contacted by a customer who processes crushed limestone. As expected, this generates a lot of dust that permeates everything in the area. If you’ve ever had dry walling done in your home you know what I mean.
The equipment used in this process utilizes extremely large and expensive air cylinders. Although wipers are installed to scrape the dust off the actuator rod as it retreats back into the cylinder, some of the abrasive limestone dust gets past or embedded into the wiper.
What gets past the wiper enters the cylinder and destroys the piston rings and the cylinder cannot hold pressure. What gets imbedded into the scraper scores the rod surfaces causing the seals to leak.
Several times a year the cylinders have to be taken apart, new piston rings installed and the rod sent out to be metalized and re-ground. The sheer size of these require a rigger to take them offline. Turn around time usually is a month. The process is time-consuming and expensive.
EXAIR suggest installing a model 2409 Air wipe around the shaft to blow the contaminants off the cylinder rod as it retracted into the cylinder. The customer reports that they can now go a year between rebuilds.
The following application example comes to us compliments of our German distributor.
The end customer manufactures stainless steel parts that go into production of a clothes washing machine. The customer wanted to blow off a stainless steel, round part used to fabricate the washing machine drum. Previously, they were using a home-made blow off system that consisted of the typical, flattened pipes loosely referred to as “nozzles”.
After thorough consultation with our distributor representative about which EXAIR nozzle would be a good choice, the customer opted to use (4) Model 1122 2″ Super Air Nozzles in the application to blow off the stainless part. The customer was not instantly satisfied with the force generated onto the target. And so, after more consultation, the customer increased their line sizes to eliminate all restrictions to the compressed air flow to the nozzles. They also purchased a model 1132SS Shim set to allow for adjustment of the airflow gap on the model 1122 nozzles and they were able to find a suitable setting that produced the desired dryness result on their product.
Green manufacturing, energy efficiency, green energy and energy savings are all phrases we use for our focus upon lowering our energy consumption. Fortunately for EXAIR, our products have been green longer than the focus and the nifty phrases have been around. Our Super Air Nozzles, Super Air Knives and Super Air Amplifiers are the most efficient (lowest air consumption) compressed air products in the industry.
But many people do not also realize that when they decrease their air consumption with our products, they also increase something very important – SAFETY. Our product line is not only engineered and manufactured for saving energy but for saving lives. All of EXAIR’s products meet or exceed the OSHA standard 1910.242(b) which states the static pressure on the outlet of a compressed air product cannot exceed 30 PSIG.
High pressure at the outlet of a compressed air blow off application is typically found when using open tubes or pipe, or pipe with drilled holes. Pressures which exceed 30 PSIG can inject air into the bloodstream and cause an embolism, an air bubble obstructing a blood vessel and it can be life threatening. EXAIR products have been engineered to use high inlet pressure (80-100 PSIG) but remain below the 30 PSIG out the exhaust. The high inlet pressure allows us to maintain high velocity outlet air flow which produces higher force levels than low pressure applications.
Another safety feature which is engineered into EXAIR’s blow off products is the low sound levels. Again our products produce some of the lowest decibel levels in the industry. This attribute helps with worker comfort by keeping the work environment quiet. Most of our air nozzles would not even be noticed in a typical manufacturing environment.
So replacing that open pipe or tube with an engineered air nozzle or removing the pipe with drilled holes to leave room for a Super Air Knife will certainly provide you with some green energy savings which will make the boss happy. But it will also create a safer work environment which will keep the boss and the employees happy – it’s a win-win.
Iron smelters have high voltage services coming into their facilities. With transformers these are reduced to lower usable voltages. This particular customer had a transformer installed in an area were the air was stagnant. Without adequate air circulation the transformers overheated and eventually failed shutting down sections of the plant.
EXAIR suggested they install a model 110054 Super Air Knife positioned over the cooling fins. The ability of the air knife to deliver huge volumes of air, more than enough air showered the cooling fins to keep the transformers cool.
Installation was simple and with no moving parts, there was no maintenance. The customer was more than satisfied with the performance and duly impressed as to the ease of installation.