A greeting card manufacturer used a liquid coolant plastic nozzle to provide an air assist to divert greeting cards to an auxiliary straight conveyor. Without the air assist the cards would bounce and fly from the conveyor leading to a loss of products and more maintenance.  They used what they had on hand which was a coolant nozzle pictured below.

This nozzle was run at a fairly low pressure of 10 PSIG, but still used 7.8 SCFM at 10 PSIG.  The nozzle worked well, but if run for 24 hours over 250 working days, it costs $702 to supply air to the nozzle. The customer utilized (40) nozzles in their plant which cost them $28,080.  Also, the nozzles were incredibly noisy, since they were designed for liquid flow.

Our customer decided to upgrade to an engineered air nozzle after some time. They needed to cut their air consumption, but still get the job done.  They tested our 1″ Flat Nozzle, but with the standard 0.015” shim it used 5.7 SCFM of compressed air at 10 PSIG. This would be a savings, but after a quick conversation with our Application Engineers, the customer decided to install a 1″ Flat Super Air Nozzle with only a 0.005″ shim. This nozzle 1126-.005 only used 0.9 SCFM of compressed air at 10 PSIG of inlet pressure.  Replace their 40 liquid coolant nozzle would save them 6.9 SCFM per nozzle. 276 SCFM if all 40 nozzles were replaced. Saving 276 SCFM lowered energy bill for their air compressor by $24,840 anuually. Which would mean the simple ROI for $41, 1″ Flat Super Air Nozzle would be 17 days!

Call an Application Engineer today to see how we can help you save thousands of dollars.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com