Don’t Get the Cart Before the Horse

I’ve recently taken up a new hobby – competitive shooting. As with all hobbies it involves $$$. Ammunition is especially expensive. To become competitive requires trigger time and many rounds of ammo. So I got the bright idea of reloading my own. I purchased all the equipment to mold and reload them, then I came to a major roadblock…availablity of lead to melt down.

When I was a kid, I molded fishing sinkers. Service stations were more than glad the give me their old wheel weights. Things have changed since I was a kid. Due to government regulations they have to document them as hazardous waste. Even the scrap yards are reluctant to sell to me. So the moral of the story is to think a project through to its end before executing.

The same moral applies to manufacturing. I am sure some of you have experienced getting a new piece of equipment only to find out that it drained your compressed air system. Someone did not think the project through to its end before committing. Now you are stuck with a piece of capital equipment that you have to find a way to use without shutting down the rest of the plant.

There is an option to consider before buying a new compressor for added capacity.  Installing EXAIR engineered nozzles throughout the plant to reduce wasteful air consumption. These have been proven to dramatically reduce demand on your compressor system.

As an example, an engine plant needed to reduce air consumption on their transfer lines. They acquired a new line from a sister plant and they ran out of air. They replaced all their open pipe and conventional nozzles with EXAIR engineered nozzles. With the newly acquired capacity, they not only were able to run the additional line, but were able to shut down a 100 horsepower air compressor.

EXAIR would like to help you save compressed air too. Give one of our application engineers a call 1-800-903-9247.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax   (513) 671-3363

Super Heroes and the Crew at EXAIR

Growing up I think nearly every child has a Super Hero that they believe is the best.  All through growing up my number one Super Hero was Spiderman.  The close second was Cyclops from the X-Men.  For most the Super Hero is about being able to help others while still having a normal life.  It’s about being able to find balance and let’s not forget about the super powers.

For me the Spiderman Comic series was one with best message to its readers’.  This is because Peter Parker didn’t live a lavish lifestyle, he was a geek that just happened to encounter serious of unfortunate / fortunate events.  He always had the same message to not stoop to the levels of evil and to also help those in need.

For the most part I am pretty sure none of us here at EXAIR have super powers.  We do however do our best to help people that may be in trouble every day that we are here.  This can in fact some times even save you from getting into a sticky situation.  Imagine this – the dastardly OSHA inspector (dastardly for illustrative purposes only) has pointed out a safety violation (that actually sounds rather helpful) in the good citizens plant in the form of an open pipe blow off. EXAIR saves the day (and the OSHA fine) by outfitting the open blow off with one of our Super Air Nozzles (wow, we even have an appropriate superhero-ish product name) which can’t be dead ended thus stifling the OSHA inspectors power and increasing safety for the model citizen. In true comic book form we should go on to say that the entire population of that comic book town rests easier and the children are clearly happier as illustrated in a colorful, sunshiny last page…

The point is we’re here to help, so feel free to contact us about your compressed air application.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Oil Palm Fruits

The photo above shows African oil palm fruits.  These fruits are high in oil content and are processed to create a cooking oil in used frequently in Southeast Asia and around the tropical belt in Africa.  Recently, a palm oil producer came to me for advice about how to clean and dry these fruits as they passed along a processing line.

Not knowing much about the fruits, I did a bit of research to discover that their harvest and use is not only common, but growing.  The palm oil extracted from these fruits contains more saturated fats than canola, corn, linseed, or soybean oil.  This high content of saturated fats means that the oil can withstand extreme heat (when used in deep-frying applications) and resists oxidation.  These features, coupled with cheaper prices, has led to an increased demand for palm oil.

The end use in this application was both to clean and dry any residue on the oil palm fruits.  After receiving a sketch of the design from the operations manager, I recommended the use of our Super Air Knives.  We came to a conclusion to use the design in the sketch below.

The Super Air Knives will be installed to create an arch over the oil palm fruits.  Using dimensional values supplied by the customer I “trigged” out the angles using various Super Air Knife lengths, and determined the 12″ to be the best fit.  This length created a 57 degree angle from horizontal and left just enough room for a 36″ Super Air Knife across the top.  See the sketch below for a visual representation.

As we typically do, I recommended that the Air Knives are installed so that the air flow exiting the knife will contact the material at an approximate 45° angle of attack.  The debris from the fruits is to be given a collection system housed under the chain conveyor.  Pretty nice system!

Exchanging sketches and building solution systems around ideas is what we do best.  If you need help with a solution, give us a call.

Lee Evans
Application Engineer
leeevans@exair.com
@EXAIR_LE

Bigger May Be Better…Sometimes, It’s Just Bigger

It’s been a while since I wrote about any Boy Scout activities. Truth is, for an organization that promotes outdoor activities, we slow down a little during the summer months, especially Cub Scouts. This past weekend, though, our Webelos (4th/5th Graders) planned an outing to our neighborhood park for a little stargazing, in order to earn our Astronomy Belt Loops, which are part of our Scientist Activity Pins, which are part of the coveted Arrow Of Light…the only Cub Scout patch that’s carried over to the Boy Scout uniform. In addition to learning how to focus a telescope, and discussing of some of the cool stuff that’s strewn throughout our universe, we also needed to:

“Draw a diagram of our solar system – identify the planets and other objects.”

Now, we could have drawn this out on poster board, fairly easily. But I thought it might be cool to give the boys a sense of the enormity of space, by laying out different sized spheres across a big open field. I found a large exercise ball (about 20” diameter) in my basement…I knew it would be either the Sun, or Jupiter. The math revealed that if I used it as the Sun, though, most of the planets would be smaller than golf balls, and I didn’t want to lose them in the field. So, I used it for Jupiter, and found another large play ball to represent Saturn, a soccer ball became Uranus, a volleyball served as Neptune, tennis balls stood in for Earth and Venus, and a few smaller rubber balls became Mercury, Mars, and the recently downgraded Pluto…which, as a child of the 1970’s, will always be a planet to me.

I didn’t have a ball big enough for the Sun in this scale, so I sat some camp chairs out in a circle, to scale…it was twenty feet in diameter. The whole model stretched over 400 feet across the field. I got lucky, in that this was just about the distance from the parking lot to the treeline.

It was a fun exercise for an unapologetic math and science fan. This morning, I got another opportunity to indulge my inner math geek, as I assisted a caller in selecting the appropriate Line Vac for an application. Turns out, he wanted to convey material that is very similar to the plastic bead tumbling media that we performed controlled testing with in order to obtain some “baseline” conveyance data.

The caller wanted to weigh the compressed air required for different sized Line Vacs against the conveyance rates achieved. That’s where it got interesting: we started with the 2” Models…turns out, the 2” Heavy Duty Line Vac consumes 66% more air than the 2” Standard Line Vac, but only conveyed the material 50% faster. Now, this was the fastest we could convey, but since he didn’t need the speed, he wanted to explore efficiency, to minimize the load on his compressed air system. The 1-1/2” Standard Line Vac turned out to meet his needs the best, using 27% more air than the 1-1/4” size, but producing a conveyance rate increase of almost 60% over the smaller unit.

So, I got to find out twice this week how effective it can be to apply a little math to gauge the scale of a project. If you have an application to discuss, even if it doesn’t involve scaling out the relative sizes and orbits of celestial bodies, or even air operated conveyor efficiency, give me a call. I may try to find a way to quantify the solution anyway…just so you know.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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