Chip Trapper Makes Coolant Last 6 Months Or More!

EXAIR's new Chip Trapper
EXAIR's new Chip Trapper

We’ve just been notified by “Plant Engineering Magazine” that their readers have named our new Chip Trapper “Product Of The Year”! That’s a very prestigious award and on behalf of all of us at EXAIR, thanks to all of you who voted for Chip Trapper. We also thank the people at “Plant Engineering” for their consideration.

Each year, “Plant Engineering” assembles a group of engineers and technical experts who review a long list of products that were made available in the past year. They narrow the list to come up with 112 finalists – companies they feel have offered something new and innovative. They show the 112 products in their November print and digital issues of the magazine and provide only the subscribers of the magazine a ballot to vote on their favorite product.  (Of course, companies with entries don’t receive ballots to keep it fair and honest.) Their circulation is almost 87,000 recipients!

If you haven’t seen Chip Trapper in action, please take a few minutes to watch our video.  Anybody who works in a machine shop understands why this product is a big deal. When the coolant that flows from those coolant nozzles slows to a trickle, you can easily end up having to take half a day (of lost production) to find the clog, clean the machine and replace the coolant. It usually ends up happening at a time when parts need to be finished by a deadline too! Using the Chip Trapper for only several minutes each week can make coolant that used to last only 6 weeks now last 6 months or more. Equally important, it gets rid of that nasty rancid coolant smell that can make you feel nauseous.

Are there other products out there that solve this problem? Not exactly! Most don’t work very well and can easily cost twice that of a Chip Trapper. We’ve tried a number of the other products in our own production and were never really satisfied with them. A lot of you who work in machining environments have probably arrived at that same conclusion. We took the problem into our own hands and developed the Chip Trapper to satisfy our own needs and those of our customers.

Is coolant management a big problem? To many we have spoken with, it is. The technical publications who have their fingers on the pulse of what is going on in industry understand this too. My January copy of “New Equipment Digest” just arrived and it has a large photo of the Chip Trapper on the front cover. They’ve also put a demo of it on their web site.  We appreciate their magazine getting the word out that EXAIR has solved a major coolant problem. If you know somebody who works with coolant, we’d appreciate it if you’d let them know too!

Kirk Edwards
Application Engineer
kirkedwards@exair.com

What exactly is an Air Amplifier?

We receive inquiries every once in a while for an ‘air amplifier’ where the customer is looking for a way to boost the pressure in their application so that they can do some specific task. The application is not anything special that requires some unusually high working pressure. The situation is that the customer’s compressed air system is poorly designed or the application using compressed air is hugely inefficient which results in an excessive pressure drop at the point of use. If you get enough applications trying to run with poor plumbing and poor set-up in place, the compressed air system can easily become over-taxed which can result in an overall system pressure drop.

An Air Amplifier, as we call it, would be a bit different from what these customers assume about the nature of operation. With our product, an Air Amplifier is a device that takes compressed air and exhausts it out, through an annular orifice, toward a target. In the process of exhausting, the Air Amplifier pulls in surrounding air volume (we measure it in SCFM). The rate at which the Air Amplifier multiplies the air volume moved is the amplification ratio. So, they amplify air volume (SCFM) and not air pressure (PSIG).

The next question becomes, “How would I use your Air Amplifier?”. In many cases, customers will need to move air toward a target for the purposes of cooling that target down fairly quickly. Another use might be to create an airflow in a duct to remove dust, fumes or other light particles. Click here for some interesting application photos

In many cases, customers will be using their compressed air to spot cool some specific area within a process and they are using an open-ended pipe to do so. This condition is extremely wasteful, unsafe and not as effective as it could be. For example, if a 3/8 NPT open pipe were blasting away on a target at 80 PSIG, that pipe would be consuming roughly 95 SCFM to do the task at hand. If that pipe simply had a 2″ Super Air Amplifier screwed right on the 3/8 NPT pipe thread, the air consumption would automatically drop to 15.5 SCFM and the customer would be moving 341 SCFM out toward their target; more than 3 times the air volume they were moving with just the open pipe; and with just 16% of the original compressed air as compared to the open pipe.

Air savings like this single example are an everyday occurence for customers who call in and get help with their cooling, blow-off and drying applications. The really interesting part is that 80 SCFM of air volume is saved from this one application and can now be used in other areas of the plant or just claimed as straight forward air (energy) savings. And so, if we can solve an individual application like this one that frees up compressor capacity for other applications, the other kind of  “air amplifier’ (read pressure booster) really becomes un-necessary for the customers original assumed purpose.

Neal Raker
Application Engineer
nealraker@exair.com

The Answer My Friend is Blowing in the Wind

As much as I enjoy my job, if I would have to choose another, it would be in special effects. These guys get to play with some neat stuff and on occasion they call us for help.  A special effects artist contacted me wanting to show how a third of the Mount St Helen’s mountain top blew away. He needed to create an explosion followed by dust and lava.

The lava part was easy, backlit orange mylar. The eruption took a little more thought. We came up with making the top half of his scale model from a layer of thin paper mache with a layer of sand an drywall dust underneath. To effect the first explosion, a simple firecracker breached the paper mache. Then an EXAIR Air Amplifier was turned on  sending the dust followed by the orange mylar into the air. Really Awesome!

In real life, the Mt St. Helen’s decapitation demonstrates earth’s ever-changing landscape and that nothing is permanent. In a split moment tons of mountain blew away in the wind.

 Takes me to mind Bob Dylan’s lyrics:
     “How many years can a mountain exist
      Before it’s washed to the sea?
     The answer my friend is blowing in the wind”

Joe Panfalone
Application Engineer
joepanfalone@exair.com

 

Do Health and Safety Regulations Add Cost?

Like everyone else in the manufacturing sector, I’ve struggled with ever-changing regulations. When all the groaning and moaning was over, we always seemed to  have worked our way through it. At first, compliance is not cost-effective but the drive to bottom line profitability made us think outside the box and ways to turn a negative into a positive.

Back in my machining days, we were forced to change from petroleum-based coolant to water based coolant. The stuff turned rancid, stunk worse than road kill, and presented a disposal problem. This gave birth to a new industry building in-house filtration systems so that the coolant could  be cleaned and used again. These in-house systems were time-consuming to get up and running and they were expensive.

EXAIR recently introduced a product that I wish I had available back then. It is the Chip Trapper . This product not only sucks out the machine sump, but filters the coolant and returns it back into the machine. Cost is modest and the return is high.

Joe Panfalone
Application Engineer
joepanfalone@exair.com