EXAIR Gives More Than Compressed Air Savings

EXAIR is a company that is built around saving, sustainability, and doing the right thing.  Our products focus on saving compressed air, reducing sound levels, and improving the safe operation of compressed air blow offs.   EXAIR is also focused on ways to give back to our community and better our team.  Over the past year EXAIR, through an employee sponsorship program, has given back to over 30 charities.  This program is open to all EXAIR employees and enables us to select a charity event that we wish to participate in and EXAIR will sponsor our participation. Fortunately, many events have a charitable arm associated with them and we have a great deal of events to choose. This leads to us, the employees, being able to contribute to charities we want to, but also gets us out and doing these events and staying active.

Over the past year EXAIR has sponsored employees in over 30 different charity backed events. This list continues to grow every year and this does not include the charities that we have always supported through direct donations or volunteering, for instance.

The picture below is of our 7 person team for the Tough Mudder in Kentucky for 2016, out of the 7, 6 are employees that were all sponsored and chose to support Wounded Warrior through running the Tough Mudder for the 2nd year in a row, first time in Kentucky, and third Tough Mudder for a few of us.

 

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EXAIR Crew at the 2016 Kentucky Tough Mudder

For myself, the best part of working for a company that not only gives to charities but encourages their employees to get out and participate within our communities, is knowing and experiencing these events together.   To give an idea we had five separate departments represented at just this event.

Brian Farno
Application Engineer Manager “One Tough Mudder”
BrianFarno@EXAIR.com
@EXAIR_BF

 

 

Custom, Flanged Air Amplifier Solves a Fume Evacuation Problem

We blog about this topic quite a bit, and almost every section of our catalog has a page set aside just for special / custom product configurations that have been created by request from many of our customers.

This is the latest and greatest special that I have seen roll through the production area here at EXAIR.   This is a special 4″ 303 Stainless Steel Adjustable Air Amplifier with a 4″ Tri-Clamp flange on the discharge side and a 6″ Tri-Clamp flange on the suction side of the amplifier.

 

This had been an ongoing project with the customer that started with them testing a stock Adjustable Air Amplifier in the application to ensure that the performance would meet their needs.  The application was to boost a low flowing fume exhaust that was causing slow downs in their production line.  Fans and other traditional methods would require maintenance and would wear out.  The stock Adj. Air Amplifiers exceeded their performance needs but did not easily mount into their duct work because they used all standard size tri-clamp fitting in the ducting, so the next step was to see if we could manufacture a Special Adjustable Air Amplifier just for their needs.  The dimensions of the existing Adjustable Air Amplifier came close enough we were able to easily create a Flanged Adjsutable Air Amplifier that would clamp straight into their existing duct work, exceed their performance expectations, help their process, and be ready to ship within a very reasonable lead time.

Like we have said before, if a stock, cataloged, product doesn’t fit your application exactly, contact us and let us find a way to customize and fit the need.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Static Problem in Plastic Tube Manufacturing is Solved

A common question that we get about Static Eliminators is “Where is the best place to install them within our process?” While there is a definite strategy to mount the Static Eliminator at the last possible point before the application problem occurs, in some instances, you still may have to use more than one Static Eliminator in different locations.

A customer was working with plastic tubes for packaging that were roughly 1” (25mm) in diameter by 6” (152mm) long. At the beginning of the process, an operator would remove the plastic tubes from boxes and manually stack them in a hopper.  They had a model 111012 Super Ion Air Knife mounted at the top of the hopper blowing down on the tubes.  This helped to remove the “shock” hazard that previously existed in loading the hopper.  To continue with the process from the hopper, the tubes are moved into an elevator and raised up to a feed chute in single file.  They would roll down a feed chute before they would be dropped onto a conveyor belt.  Just as the plastic tube would drop, static created from friction generated by the rolling action would cause one side of the plastic tube to “stick” to the prior tube, causing a jam in the system.

Jamming Area of Plastic Tubes

Jamming Area of Plastic Tubes

The customer was looking for a solution to stop the jamming. He had already mentioned that he was using the model 111012 Super Ion Air Knife at the hopper and wondered if it was working properly.  A quick question quickly verified its operation.  I asked if the operators were getting shocked from loading the plastic tubes into the hopper.  He stated that they were not.  So, the Super Ion Air Knife was removing the static charges as intended to keep the operators safe. The customer also sent pictures of the operation so I could better understand his process.  From the photos, the plastic tubes were right up against each other lengthwise in the chute.

Static charges were re-generating through the movement of the parts going through the loading elevator, moving up to the feed chute, and sliding down to the conveyor; the plastic tubes were rubbing and rolling against each other.  As with any non-conductive materials that are rubbed, slide against one another, or peeled, static electricity has a very good possibility to be generated or re-generated as in this case.  Even though the static was being removed at the hopper, the friction between the plastic tubes caused the static to regenerate.

Since static was affecting the feed of plastic tubes onto the conveyor, we needed to re-focus our attention in this area. The problem area in this application has now become the feed chute. After talking things over with the customer, model 111006 Super Ion Air Knife  was mounted above the end of the feed chute to provide an ionized airflow.  It would be facing the length of the plastic tube and angled upward along the incline of the chute, setting up a good counter flow between the parts and the ionized air.  Because static is a surface phenomenon, the ions have to hit the exposed surfaces to neutralize the charge. This arrangement would blanket the top surfaces of all the plastic tubes in the feed chute with ions as they roll by, neutralizing the charges before they became a problem at the end of the chute.

Super Ion Air Knife

Super Ion Air Knife

This is only one example of EXAIR Static Eliminators reducing a static charge in packaging applications. The product works well at eliminating the jamming, feeding, tearing, discharges to operators and other similar problems encountered within the packaging environment. Do you have a similar feeding application that you feel could use some help from static elimination?  If so, we’d love to hear from you. Contact us with your application questions today!

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Engineered Flat Air Nozzles Remove Oil from Parts & Eliminate Packaging Rejects

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Coating station for tapered roller bearings

A few months ago I helped an end user find a solution to remove residual oil from u-joints (technically termed “spiders”).  As the u-joints moved through the application, lubricant would accumulate in the bottom of a collection area.  This accumulation presented problems in the next phase of the process, and a method to remove the oil from the u-joints was the perfect solution.

IMG_6618

Transfer “gutter”

Fast forward a few months and a similar application has surfaced.  In the new application, tapered roller bearings are coated in lubricant and then transferred from the coating station through a metal gutter and into a transporter.  At the end of the process the bearings are placed into packaging, and excessive oil is leaking through the packaging.  The affected packages are deemed defective, resulting in rework for the bearing manufacturer.

IMG_6616

Bearing transporter. After moving through this stage of the process the bearings are packaged for delivery.

Similar to the original application, we found a solution through the use of an engineered air nozzle setup.  Model 1122 Super Air Nozzles and 12″ Stay Set Hoses can mount to the coating station using magnetic bases.  The airflow from the nozzles are then aimed over the bearings to remove excessive lubricant, effectively removing the root cause of the packaging defects.

By removing the excess lubricant at the lubricating station (which is equipped with a slotted table), the excess oil is channeled through the table and into a collection bin.  The end user is then able to reclaim the same oil which would leak through the packaging and cause defects.  So, in addition to solving a problem related to defects, the end user is also able to reduce wasted lubricant in the process.

Reducing defects and lowering material use in this application is made possible through the correct application of an engineered blow off solution.  If you have a similar application or think an engineered solution may benefit your application, contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

I Love It When They Show The Math

In every math or science class I ever took – from high school Algebra I, to CHEM101 in college, or a variety of classified material courses in Naval Nuclear Power School – it was always good form to show your work. And by “good form” I mean “necessary to avoid an F.” I’ve found, through helping my teenage sons with their homework (whether they want me to or not, but that’s another story,) the same rules apply today. And rightly so.

My oldest is slightly (at least) more interested in athletics than academics. Sunday night, as I was going to bed, I saw him in the living room. His face was not obstructed by his cell phone and he didn’t have his headphones on, so I saw a rare opportunity for a real-time conversation. He was watching game 7 of the NBA Championship, and it was near enough to the end of the game that I figured I could watch it with him and not sacrifice too much desperately needed sleep.

If you watched the series, you saw some phenomenal play by both the Cleveland Cavaliers and the Golden State Warriors. If you saw the end of game 7, you saw “the block” – Cleveland’s LeBron James came out of NOWHERE to rob Andre Iguodala of a quick two points on a breakaway lay-up. During the obligatory replays, I kept thinking that what James had done might border on the physically impossible. Then, ESPN’s “Sport Science” reel put into perspective just how close to that border he came:

Now, we don’t have anyone who can chase down a professional athlete and jump 12 feet in the air to take a basketball away from him, but we DO have a staff of engineers who can test air blow off products and “do the math” on how much better a fit to your application an EXAIR Intelligent Compressed Air Product would be. Our Efficiency Lab service is free and tests your current product to provide you a report comparing air savings, noise reduction, force values and a simple return on investment.

In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.

In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.

Do you want to find out how much quieter and efficient an EXAIR Intelligent Compressed Air Product might be than what you’re using now?  Give me a call…you can try one of our products in your facility, or we’ll test one of yours in ours.

Russ Bowman
Application Engineer
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Congrats Cleveland, The Cavs Are NBA Champions!

Living in Cincinnati, it’s somewhat of an unwritten rule for sports fan that we don’t root for any Cleveland professional sports teams. Take for example the Cleveland Browns and Cincinnati Bengals, in-state rivals that just happen to both play in the AFC North division of the National Football League. Both of these teams were also founded by the same coach, Paul Brown, and share the same color orange in their uniforms. In Major League Baseball you have the Cincinnati Reds and Cleveland Indians. The Reds were the first professional baseball team with the Indians following suit just a few yeas later. Although not league or division rivals, they still compete in interleague games dubbed by fans as the “Ohio Cup” or the “Battle of Ohio”.

When it comes to basketball, Cincinnati doesn’t have a professional team anymore so there isn’t any real feel of loyalty to any particular franchise. In Cleveland though, they have the Cavaliers who have been successful over the past few years, albeit with a little bit of controversy from one of their own – Lebron James, who was raised nearby in Akron, Ohio. I am a long time basketball fan who appreciates great talent. What I don’t care for is the “me first” attitude that has become all too common lately with professional athletes. The “King”, as James refers to himself, abandoned “his City” back in 2010 to join the Miami Heat organization to chase an NBA championship. He made the announcement in a live broadcast event called “The Decision” in which he announced he was ‘taking his talents to South Beach (Miami) and promised “not one, not two, not three…… championships”, which drew critics in the national media, as well as drawing the ire of fans back in Ohio. While he did help guide the Heat to the title in 2012 and 2013, he also lost a couple Finals appearances in 2011 and 2014.

At the end of the 2014 season, James did a little bit of soul searching and decided to return home to Cleveland to deliver a championship. His first year back, 2015, the Cavs finished the regular season with a 53-29 record and made their way to the NBA Finals. During the Finals run though, the Cavs lost their starting point guard and their starting shooting forward to injury. Needless to say this completely changed the teams dynamic, as without the extra support, Lebron was only able to carry his team two victories and they lost the series 4-2 to the Golden State Warriors.

Fast forward to this year. For the majority of the year, the two best teams in the NBA were the same as last year with Golden State leading the Western Conference and the Cavaliers leading the East. The Warriors broke an NBA record for the most wins during a regular season, finishing with a 73-9 record, breaking the 72-10 record previously held by the Chicago Bulls (led by the greatest of all-time, Michael Jordan – IMHO). Both teams had their struggles through their respective playoff runs but as fate would have it, would meet again to determine a champion. Golden State hosted the first two gams and pretty much manhandled the Cavs before heading to Cleveland with a 2-0 record. Game 3 was the polar opposite of the first two games, as Cleveland was able to secure game 3 with a 120-90 victory. The next game seemed to end all hope for the Cavs as Golden State dominated the final quarter to lead the series 3-1 before heading back to California.

Now, there has NEVER been an NBA team come back from a 3-1 deficit to win the title, so things were looking pretty bleak for Cleveland. It seemed the man who promised so much to “His City” was once a again going to fall short of delivering that elusive Championship. But as fate would have it, somehow, someway, the Cavs were able to regroup and come out completed dialed in and focused on the goal at hand. Well, really it came down to 2 key players for the Cavs, the starting point guard and Lebron James. Both players played out of their minds and willed their team to victories in game 5 and game 6, setting up a much anticipated game 7 finale.

Game 7 held up to the billing, it was awesome, even if you’re just a casual sports fan. The contest went back and forth with neither team getting out to more than an 8 point lead. The game came down to the last minute as both teams were tied with the Cavs point guard hitting a clutch 3-pointer that gave Cleveland the lead. The Cavs were able to hold on and win by 4 points, securing Cleveland’s first championship in almost 50 years. Lebron finished with a triple-double, only 1 of 3 players to hold that honor in Game 7 of the finals and was named the series’ MVP.  Lebron’s average for the Finals were 30.2 points, 11.3 rebounds and 8.5 assists. Basically, he lead every recorded stat out of every player, he undoubtedly led “his” team to the title. It really was a fun series, even for the casual fan.

So congratulations Cleveland!

EXAIR has played a part in the fun of the NBA as well. Our Line Vac Air Operated Conveyors have been incorporated into a specially designed Gatling gun used to launch T-Shirts into the crowd at Milwaukee Bucks’ games. We’d like to see the Cavaliers get one of these too!

Check out this video:

 

Justin Nicholl
Application Engineer
mailto:justinnicholl@exair.com
@EXAIR_JN

 

Patented Nozzle is a 2016 Flow Control Magazine Innovation Awards Nominee!

No Drip Atomizing Nozzle

No Drip Atomizing Nozzle

The patented (no longer patent pending) EXAIR No-Drip Atomizing Spray Nozzles have been nominated and are a finalist in the Flow Control 2016 Innovation Awards.  The No Drip Atomizing Nozzles are just a portion of the entire Liquid Atomizing Nozzle products that EXAIR Offers.   The No-Drip’s patented liquid shut off valve design eliminates the need for a separate pilot air line to positively shut off liquid flow ensuring there are no drips or excess flow from the nozzle.  These are ideal when dealing with fine surface finishes, costly liquids, or intermittent spraying needs.  The nozzles are offered in both pressure fed liquid and siphon fed liquid versions.

For the pressure fed version, the nozzle will require both compressed air and a pressurized liquid source. Both pressures can be adjusted independently giving a large spectrum of adjustment to fine tune the spray pattern and droplet sizes.  The siphon fed nozzles can draw liquid up to 36″ vertically or be gravity fed up to 18″ overhead.  This makes installation quick and easy when a pressurized liquid source, or liquid pump is not at hand.

The No-Drip Atomizing Spray Nozzles have also proven themselves in many applications, you can even read about a few of them here on our blog, links below.

https://blog.exair.com/2013/11/13/no-drip-atomizing-nozzle-improves-deep-drawn-metal-process/

https://blog.exair.com/2016/03/22/atomizing-nozzles-have-added-benefits-that-can-really-help/

2013 Innovation Awards

2013 Innovation Awards

 

Some of the reasons the EXAIR No-Drip Atomizing Nozzles were selected for these applications are the patented no-drip valve, their ability to atomize liquids to a range of 22-71 micron droplet size, the ability to fit into a tight space as well as the many spray pattern options.   These features have ranked the nozzles as a finalist in Flow Control’s 2016 Innovation Awards.

We are very grateful if you choose to vote for our nozzle at the link below. Please vote.

http://www.flowcontrolnetwork.com/innovationawards/

Voting is only open through July 31, 2016.  We’ll make sure to keep you updated if we win!

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

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