A home use for Static Eliminators

The chill in the air can only mean one thing here in Ohio, the end of Summer.  With the end of Summer the temperatures start to drop and the air starts to dry up.  With the dry air comes static charge.  You start noticing every time you get out of your car you end up getting zapped, when you go to shake someone’s hand you get another zap, even hobbies can become susceptible to static.  This is exactly what happened to me two nights ago.

My nephew has a remote control car that he absolutely loves to drive fast and crash with.  Well the remote control cars of today tend to have a little more power than those that I used to play with.  So all the crashing and stopping and going had stripped the spur gear out that is driven by the dual motors.  You can see the remains of the gear below.

While shopping for parts to fix his car I decided he needs a friend to run the R/C cars with so I got myself one.  (Of course it had to be faster than his.  I mean who wants to lose a race to a kid.)  I was done with his car and took the car I purchased out of the box.  This truck came pre-assembled unlike the ones I used to get and all I had to do was add some accent decals if I wanted to.  Of course I decided I could make it look like the one on the box without any problems.  This is where the problem started.   

You see, the body of the truck is plastic and after wiping it down to ensure it was clean for the decals I had loaded it up with a nice static charge.  Then by peeling the decals off the backing paper I generated some more static onto the decals.  This resulted in me getting the decal within an inch of the body and the static charge would pull the decal onto the surface before it was lined up.  After peeling the same decal off about 3 times because of this I really began to wish I had an Ion Air Gun or even a small Ion Bar in my garage to help with the problem.  

With a quick blast of ionized air over the body inside and out, eliminates all the static and makes the decal application process much easier.   Now I just have to work on that whole steady hand part of it.  Eventually it will be done and look near professional.

Brian Farno
Application Engineer

I’m So Excited!!!

This past weekend I noticed my son’s shoes were getting tight so we went out to find a new pair.  He wanted this, then he wanted that, and when we got to the store, it still changed a few more times.  Then, when he finally saw a pair he liked, he zoned in on them and had to have them.  They were a great looking shoe I would’ve bought for myself (tried to, didn’t have my size) and to make it even better they were less than I wanted to spend and were 50% off too!  #Winning!

Later that night my son asked me if he could sleep in his new shoes.  Before I could answer, he said to himself “No, they would scratch me”.  It made me think back to when a new pair of shoes made me so excited.  I was the same age at the time (three) and I remember the adoration I had for my first pair of Nikes.  Like father, like son.

But, as I am accustomed to do, I thought more on the matter and asked myself what do I feel that way about now?  There were my immediate answers – my family, close friends, philanthropic related activities/studies – but I felt as though I needed a more topical answer.  Something more tangible to enjoy…

Enter the 1108SS Atto Super Air Nozzle from EXAIR!  I LOVE THESE!  Sometimes I have daydreams of making studded belts with a million of these little air nozzles, or spiked collars to sell at a heavy metal concert…  I think about the possibilities of going even smaller and becoming a part of the nano-tehcnology of the future.  Using our futuristic nozzle designs on a microscopic level – the possibilities are endless!!!

But, for now, I’m here at EXAIR.  Just waiting for the right application to come along and utilize the new air nozzles which have been tirelessly perfected…  Can you help me find a home for these destined-to-be classics?

Lee Evans
Application Engineer

The Cost of a Leak

Leaks can be costly. If you have a leak in one of your vehicle’s tires, it can cost you more in gas…if you’re lucky. That leak can lead to a blowout, which could cost you your car, or maybe your life. Don’t drive on a leaky tire.

If you have a dripping faucet, it may not bankrupt you – it might be adding a buck or two to your water & sewer bill. It might cost you some sleep, if you can hear it at night…just the thought of it puts an Edgar Allan Poe tale in my head. Most of the time you can fix it with basic hand tools and an o-ring or washer that you can find at any hardware store.

Leaky toilet tanks, on the other hand, can really set you back. A continuous leak into the bowl can set you back $10 a month, or more. Not to sound like a bad prank phone call, but if your toilet’s running, you better catch it, and quick.

Compressed air leaks can be especially costly, because compressing air is an expensive operation. If you have a large leak, you may be able to hear, or even see it. You have to fix those, and you know it. Small leaks are harder to find. Good news is, individually, they’re not costing much. Bad news is, they add up…quickly. Worse news is, they don’t fix themselves. Or find themselves.

If you’re ready for some more good news, here it is: no matter how small a compressed air leak is, it’s producing ultrasonic sound waves. See, during a leak, a fluid moves from high pressure (inside the system) to low pressure (the atmosphere.) As it passes through the leak site, a turbulent flow is generated. This turbulence has strong ultrasonic components, and, usually, the larger the leak, the greater the ultrasound level. “Ultrasonic” simply means that these sound waves are higher in frequency than our ears can hear. However, there are devices that can not only detect these ultrasonic sound waves, but discern them from the industrial din that surrounds them. And we have such a device: the EXAIR Ultrasonic Leak Detector.

I recently had the pleasure of working with a gentleman who was installing a refrigeration system in an ice rink floor. As you can probably imagine, it takes miles of refrigerant tubing to make enough ice to play hockey on. Regardless of the skills and attention to detail of the installers, the sheer number of joints means that there’s a good chance a leak will develop somewhere. This was on the caller’s mind, so he wanted to know if this might be a good application for our Ultrasonic Leak Detector. After I explained the theory behind the device, he agreed to give it a try. All construction leaks were detected when they applied test pressure (air) to the system. After fixing these initial construction leaks, the system was filled with refrigerant, and was started up, leak-free.

Leaks can be costly – do the math.  Or better yet, EXAIR Corporation President Bryan Peters already has.  Whatever’s leaking- steam, pressurized gas, refrigerant, or compressed air – it can be easily located with the Ultrasonic Leak Detector, even in noisy industrial environments.

Russ Bowman
Application Engineer
EXAIR Corporation
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My Secret Box – FAIL?

The Secret Box – everybody should have one, if you don’t have one – find out if you can make one. Mine holds some prototypes, failed ideas, and failed wacky solutions I have attempted over my years here at EXAIR. There are also a couple of successes.

The box represents, in some way, the flexibility of EXAIR to allow new ideas and their willingness to take risks on a crazy (read creative) idea now and then. Many of these trials and failures also kept a project going, they were just a momentary stop along the way to a solution.

It also gives me a chance, when having conversations with newer Application Engineers, to say something like “let me look in my secret box” and then have a discussion about something we have tried in the past. This has been helpful in providing information to prevent ending up at the same failure twice, but perhaps developing a new failure and or solution.

If you have an application which may benefit from some creativity let us know, EXAIR has been encouraging it for 28 years now. And don’t knock the Secret Box – and don’t be afraid to fail.

Remember these words of Thomas Edison:

“I am not discouraged, because every wrong attempt discarded is another step forward”

Kirk Edwards
Application Engineer



The Digital Flow Meter Saves Headaches, Time and Money

I provided a solution for a company in the tobacco revenue industry who make case packaging, wrapping and labeling machines for cigarette makers. One of their sales reps contacted me with a concern about one of their machine models which demands a great deal of their attention due to a requirement for compressed air. This machine needs a small amount of air for certain features of the machine to work properly.

This particular salesman explained how often they try to remotely trouble-shoot the performance problem of their machine, knowing they are dealing with an air supply issue, but consistently end up arranging flights to visit the customers. The additional costs of trying to solve this common problem is now a real cost burden. He and the service manager were seeking a solution to the problem when they discovered EXAIR’s Digital Flow Meter.

The flow meter is available in many sizes, including the 1″ they needed to fit on their machine’s air inlet. Once outfitted to the machine and hooked up to the air supply of a customer, the Digital Flow Meter will display how much SCFM is reaching the machine. Having the feedback from the digital flow meter will provide the empirical feedback needed to convince the customers they need to supply more air in order for the machine to work properly – without needing to arrange for a service call on site.

This is just one example of where a Digital Flow Meter can save headaches, time and money. They should also be used when benchmarking the air consumption of a production leg within your plant when you implement an air conservation program – this gives you a place to begin conserving compressed air. The Digital Flow Meter will also continue to supply you with feedback about your air savings so you will have hard evidence of air and cost savings – we know your boss wants hard evidence.

A Digital Flow Meter can also be outfitted with a Summing Remote Display to provide feedback in a convenient location from air lines which may be in a difficult location. The Summing Remote Display will also provide average air use over a 24 hour period. You can also hook into the 4-20 mA output of the flow meter to collect data about your air use.

If you are curious about beginning to save compressed air in your production process or providing feedback to your customers about the requirements for your machine, the Digital Flow Meter is a good place to start.

Kirk Edwards
Application Engineer

I Used to Like Euchre, but Now I Just Think About Static

Euchre was a game I had heard of in highschool and finally learned how to play in my senior year.  Before that we were big Hearts and Spades fans so Euchre wasn’t too far out of the realm.  We played the game before school, during lunch, and a lot of weekend nights where we were all just hanging out.

When I went to college it seemed to be the popular game of choice so the game continued.   I can’t really remember a weekend where a game of Euchre wasn’t being played at some time.  It wasn’t until I was in college that I realized the amount of strategy that went into a good solid hand of Euchre and every time my fraternity brothers and I get together it’s always a part of the night.

The interesting part now is, every time I play a card game I think of a recent application that is rather common for us.  You see when playing cards are being made the card stock all has different humidity levels within the stock depending on where the cards are shipping to.  When the manufacturer runs a card that has a low relative humidity it tends to generate static.

The sheets of printed cards go through a cutting dye which takes a single sheet and cuts it into individual cards.  The cards are then all stacked into one pile and sent through a sorting machine.  All the friction from being cut, stacked, and separated generates a large volume of static.  The card manufacturer I was helping was having an issue where the cards would stick in the sorting machine and not drop into the individual deck boxes.  There was a laundry list of obstacles that were not in favor of a large footprint ionizer.  The cards were traveling in a confined area along with a very high rate of speed.  (So fast you couldn’t see the space between them unless you followed a single card.)  This meant we had minimal entrainment time and very limited space to eliminate the static in, not to mention since the cards were being conveyed the friction was regenerating the static rapidly.  The solution was to install an Ion Air Jet at the separating station so the static would be eliminated at the initial point of sorting and then to blanket the individual sorting chutes with ionized air from a Super Ion Air Knife.

This allowed us to blow ionized air through the working chamber of the card sorter which not only eliminated the static on the cards and solved the card jamming issue but it also helped to blow any trim or dust into the bottom of the machine for easy cleanup.

If you have any questions about how a Static Eliminator can help with your application feel free to contact us.

Brian Farno
Application Engineer

My Favorite Time of the Year

As the season begins to change and I’m greeted by the crisp air in the morning, I realize that autumn is upon us (officially starts tomorrow).  Fall is by far my favorite season!  The cool air outside, just enough to make you appreciate the refuge of a warm house, and the harvest and food that comes this time of year are the best!  Oh yeah, and there’s football…

Football has an enormous fan base here is America, but it has had trouble becoming appealing on a global scale.  Crossing borders is not something the NFL has done well, but another sport, the UFC, has managed to do so with great success.  I attribute this success to the nature of the sport.  Mankind has always been keenly interested in fighting and combat, since our inception.

Something else that crosses borders well is saving money/time and increasing efficiency.  The products we design here at EXAIR are meant to do just that.  We focus on saving compressed air and solving application specific problems in the most efficient manner possible.  Both of these focal points have saved our clients an immeasurable amount of time and money over the years.

If you have an application in need of cost savings or efficiency improvement, contact the application engineering department at

Lee Evans
Application Engineer