About a month ago I was in the field with one of our distributors in India visiting one of their customers. We were there to make an audit of their applications which were suspected of being high volume compressed air users within the plant. The very first application we were taken to was the point where large, steel castings begin their journey through the plant. It is at this point that the castings must be cleaned of all chips and residue prior to being run through a large parts washer.
The application involves multiple personnel blowing onto large, steel castings to remove machining chips, oil and other debris to prepare them for washing. The existing air gun might have been in good condition at some point, but during our visit, we found the air gun’s trigger was secured in an open position with zip ties so it was “on” all the time. Also, there was no nozzle at the tip of the gun. It appeared to have been cut off with a grinding wheel. The fact that there was no engineered nozzle at the end made the unit quite un-safe, loud and a large consumer of compressed air. The fact that the handle was clamped in the open position also negated the effectiveness of being able to use the air only when needed. Finally, when these operators would blow into blind holes debris would exit with significant velocity, so that represented a danger to the personnel that we could also remedy with our recommendation.
After initial review of what was happening in the application and seeing first-hand what the issues were, we recommended EXAIR Model 1410SS-CS (Precision Safety Air Gun with Chip Shield).
Following is our estimate of compressed air usage for the existing air guns and calculated air savings with projected cost savings figured for 4 people operating constantly over three daily shifts. Estimated current air use per each gun = 33 SCFM. Air consumption of model 1410SS-CS = 8.3 SCFM. Net air reduction = 33 – 8.3 = 24.7 SCFM. 75% air savings. Rough estimate for per shift air savings = 47,424 Standard Cubic Feet. At $ .25 USD / 1000 SCF, the “per shift” savings could be $11.86 USD. Total daily savings = $35.57 USD.
As many who follow compressed air savings know, compressed air is one of, if not the most expensive utility in just about any manufacturing operation. And this case demonstrates just how expensive four innocuous air guns blowing in a single application can really be and how it adds to the bottom line costs that every manufacturing decision-maker is usually concerned about.
Point being, if you want to add to your bottom line, give consideration to your air blowing applications. There is usually big savings to be had which can improve the application, help the bottom line, increase safety and conserve on that ever precious resource, energy.