What do you do when you realize the existing blow off in an application is wasteful and not OSHA compliant? You call EXAIR!
In the process shown above, threaded fasteners are fed into a vibratory feed bowl, assisted by open copper pipe blow offs. Looking for opportunities to lower compressed air use, save operational costs, and lower noise levels, the end user contacted the Application Engineering department at EXAIR.
Initially our conversation focused on the required force of the blow off, current air consumption, and current noise levels. The required force was unknown, current compressed air consumption was unknown, and the noise level was given the often heard description – “LOUD! “
So, to determine the nozzle required, without knowing the force required, the end user cited the weight of each fastener. With a range of 0.017 -0.049 pounds per piece, I recommended the 1108SS Atto Super Air Nozzle. Sensing that a bit more force was desired to produce a comfortable margin of force, we moved to the 1109SS Pico Super Air Nozzle and the 1110SS Nano Super Air Nozzle nozzles for testing, with the most suitable nozzle becoming the choice solution.
After discussing force, it was time to discuss flow. Without an idea of the current compressed air use, it would be difficult to quantify the compressed air savings by installing EXAIR Air Nozzles. And, even though the compressed air use was unknown, we determined approximate flow based on orifice size and operating pressure. With an orifice of 0.109″ operating at 80 PSIG, the compressed air consumption per copper tube of approximately 18 SCFM (Based on chart value below.). The feed bowl has at least 5 open tube blow offs, resulting in a total compressed air use of 90+ SCFM. By converting to our 1110SS nozzles, the compressed air use can be reduced to 41.5 SCFM, a savings of over 50%! By installing EXAIR engineered nozzles, approximately 12HP of compressor load was removed from the system. Considering that the facility has upwards of (15) feed bowls, the savings in implementing the EXAIR solution become very large, very fast.
Lastly, we discussed noise. Open pipes can be the source of incredibly loud noise levels. The end user estimated 90 dBA or higher. The EXAIR 1110SS Nano Super Air Nozzles has a sound level rating of 75 dBA, reducing the sound level exponentially. The icing on the cake for the end user, above and beyond the compressed air savings and noise level reduction, was the safety added by the EXAIR nozzles. All EXAIR products operate below OSHA dead ended pressure requirements (OSHA Standard 29 CFR 1910-242(b)).
Applications like this are what EXAIR is all about. Meeting or exceeding existing performance levels while lowering compressed air use and noise levels, and adding safety to the work environment. If you have a similar application or need advice regarding EXAIR products, contact an EXAIR Application Engineer.