FREE TESTING!!!! EXAIR’s Award Winning Efficiency Lab Saves Air and Money

EXAIR’s Efficiency Lab is now the “award-winning Efficiency Lab”. Thank you to Environmental Protection Magazine for recognizing the value and importance of this EXAIR service.

epawinner2016_400x

 

I have blogged about this many times and we continue to help customers by using our free Efficiency Lab service that EXAIR provides to customers throughout the USA.  The EXAIR Efficiency Lab allows customers to send in their existing blow off device and we will test it for compressed air consumption, sound level, and force.  Ideally we try to take these measurements at the same operating pressure that is being supplied in the field so that we can compare it to an EXAIR product and offer the customer the best solution, the safest solution, and an engineered solution capable of saving them money through air savings and effectiveness.

Here is a recent example of  a product sent in by a customer concerned with compressed air consumption and safety of their people. The  hose they sent in was actually designed to be used with liquid coolants and was a very large consumer of compressed air.

A flexible blow off with .495" openings. Designed for liquid but used for compressed air. Enormous waste of air and a huge safety risk.
A flexible blow off with .495″ openings. Designed for liquid but used for compressed air. Enormous waste of air and a huge safety risk.

The hose shown above was being used at 40 psig inlet pressure.  The device is not OSHA compliant for dead end pressure, nor does it meet or exceed the OSHA standard for allowable noise level exposure.   The hose was utilizing 84.64 SCFM of compressed air and was giving off 100.1 dBA of sound.

OSHA Noise Level

As seen in the chart above, an employee is only permitted to work in the surrounding area for 2 hours a day when exposed to this noise level.   The amount of force that the nozzle gave off was far more than what was needed to blow chips and fines off the part.   The EXAIR solution was a model 1002-9230 – Safety air Nozzle w/ 30″ Stay Set Hose.

The EXAIR products were operated at line pressure of 80 psig which means they utilized 17 SCFM of compressed air and gave off a sound level of 80 dBA.  On top of saving over 67 SCFM per nozzle and reducing the noise level to below OSHA standard, the EXAIR engineered solution also meets or exceeds the OSHA standard for 30 psig dead end pressure.   In total this customer has replaced 8 of these inefficient lines and is saving 541 SCFM of compressed air each time they activate the part blowoff.

If you would like to find out more about the EXAIR Efficiency Lab, contact an Application Engineer.

We look forward to testing your blow off and being able to recommend a safe, efficient, engineered solution.

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

 

EXAIR Cabinet Cooler in Bahrain Still Operating Years Later, In Harsh Conditions

img-20170110-wa0010
This small NEMA 12 type Cabinet Cooler has been in operation for years. Now, two additional units are needed for new applications.

A few weeks ago I was contacted by a mechanical contractor in Bahrain about a needed Cabinet Cooler.  Their customer had an existing unit in place and needed two more for similar applications.  As with any Cabinet Cooler need, we needed to start with an accurate understanding of the heat load involved, to make sure we recommend the proper model number.

So, we used the Cabinet Cooler Sizing Guide to gather the required information and calculate the heat load of the application.  After using this information to calculate a heat load of 426 BTU/hr. (~125W), we confirmed that the existing model 4308-240 will be the correct fit for the additional cabinets as well.

img-20170111-wa0000
Even in this dirty environment the Cabinet Cooler continues to function.

The existing Cabinet Cooler has been in operation for several years without any required maintenance or upkeep.  Clean compressed air, achieved with a simple 5 micron water/dirt filter separator,  is supplied to the unit and nothing but clean cold air is fed into the cabinet.  Relative humidity is regulated by the Cabinet Cooler to 45% resulting in stable temperatures and humidity for the electronics inside the enclosure.

img-20170110-wa0009
The dirt and debris are prevented from entering the enclosure due to the design of the Cabinet Cooler. Only clean, cold air enters the cabinet. Hot air is vented away.

This application is an excellent example of the durability of EXAIR products.  With proper compressed air supply our products will operate uninterrupted and at proper performance for years.  If you’re in need of a durable solution for an electrical enclosure, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Compressed Air Flows At The Speed Of Technology At EXAIR

I don’t know that any enterprise can give you a better idea of the scope, width, and breadth of American manufacturing quite like the automotive industry:

*Pick a raw material – rubber, steel, plastic, glass, just to name a few – modern day production of all of these has been heavily influenced by the way they’re used in automobiles.

*Pick a manufacturing process – welding, cutting, molding, machining, mechanical & electrical assembly, again; just to name a few – car makers have revolutionized them all, oftentimes to the benefit of many other industries that have used…and adopted…these technological improvements.

*Pick a business.  OK; this is going to depend on where you are.  I’m in Cincinnati, Ohio.  I can be on Interstate 75 Northbound in under 10 minutes, and four hours later (and on one tank of gas, thanks to the fuel efficiency of my American made automobile,) I can be in Detroit, Michigan – the land of the “Big Three.”  And I’ll pass dozens, if not hundreds, of buildings within sight of the highway that house businesses whose largest customers are automotive industry types.

We brag on American manufacturing occasionally, because we’re proud to be a part of it, and to support so many different aspects of it.  What got me thinking about all of this was a call I got recently about our Cold Gun Aircoolant Systems, and how one might be used in a particular machining application.  They machine transmission parts and, due to the specifics of a new material and a subsequent operation, they needed to eliminate the liquid coolant.  This is a ‘textbook’ situation for a Cold Gun – the part in question is small, and just needs a quick shot of cold air during the process, so they got a Model 5215 Standard Cold Gun, put it on the machine, and turned off the coolant…forever.

With four models to choose from, we've got most any cooling application covered.
With four models to choose from, we’ve got most any cooling application covered.

This is one of, literally, hundreds of applications where EXAIR’s line of engineered compressed air products is making all the difference in the world.  If you’d like to discuss how we can help you keep up with the speed of technology, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

Conveying Plastic Bucket Handles With A Line Vac Saves Time

A packaging company was looking to convey the plastic handle grips commonly found on plastic buckets (see below pic for reference). The grips are roughly 3″ long and about a 1/2″ in diameter and they currently have an operator manually load the hopper on their vibratory feeder which is located on the 2nd floor, about 12′ away from the receiving area. The hopper is level controlled and the machine uses 3 grips per minute so as the level dropped,  the operator would have to stop the process, go down and load the parts in a box, then go back up the stairs and dump the box into the hopper. This was a very tedious process, which wasted a lot of time so they reached out to EXAIR for a more effective way to get the job done.

yellow-bucket
The plastic handles are similar to the black handle shown here.

After further discussion, I recommended our 1-1/4″ Line Vac Kit  for the application as this unit has a 1″ inside throat diameter that would easily pass 1/2″ diameter parts and deliver them to the overhead hopper. Since they were only needing to load a few parts at a time, I proposed they have the operator simply feed the parts in to the Line Vac suction line to avoid any potential blockages. Additionally, I suggested they incorporate our Model# 9040 foot valve into the process to simplify the operation and provide additional control so they are only using their compressed air supply when needed to move the parts. The foot pedal will allow the operator to activate the Line Vac each time they feed parts moving in to the hopper. Among the items this kit includes is a pressure regulator which would allow them to adjust the supply pressure to the unit, providing control over the conveyance rate and velocity at which the parts are ejected.

gh_LVthr-hd-ld_754x696p
The Line Vac Air Operated Conveyors are available with smooth or NPT threaded ends in aluminum, 303ss, 316ss or hardened alloy construction to meet the demand of a wide variety of material transfer needs.

 

EXAIR’s Line Vac Air Operated Conveyors are able to convey light materials,  like plastic pellets,  to more abrasive materials like steel shot blasting media. To see how a Line Vac might fit into your process or for help selecting the best EXAIR product for your needs, give me a call, I’d be glad to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

yellow bucket image courtesy of sammydavisdog via Creative Commons license

Super Air Wipe Cools, Cleans and Dries Extruded Shapes

We have many customers that use the manufacturing process of extrusion to make their various type of products.  EXAIR has an Intelligent Compressed Air Product that works very well with these processes to provide a drying, blowoff and cooling function.

Many types of products are produced via the process of extrusion, which is to shape (as metal or plastic) by forcing through a die.  There are many advantages to the extrusion process, including it being a continuous operation, it runs at high speeds, is good for high volume and low production costs, as well as many other factors.

The extrusion process typically requires heating of the metal billet or melting of the plastic to a high enough temperature to allow it to flow and be shaped as it it forced through the die. After the product has passed through the die and has been shaped it must be cooled and this is usually achieved by passing the it through a water bath.  Once the material has been cooled, it needs to be dried to remove the moisture, before the extrusion enters the next stage of processing, like getting cut to length or printed upon.

The EXAIR Super Air Wipe is ideal for blowoff, drying, cleaning and cooling of continuous materials such as extrusions, pipe, cable and more.

saw_2-2

The Super Air Wipe has a split design which offers easy clamping around the surface of the material, eliminating the need for threading. All Super Air Wipe models include stainless steel screws and shims.  Stainless Steel wire braided hose which is plumbed to each half, is included on sizes up to 4″ to simplify installation and plumbing. Aluminum models are rated to 400°F and the stainless steel models for temperatures up to 800°F.  Models are available in size from 1/2″ to 11″ Throat Diameters.

The Super Air Wipe provides a uniform, 360° air stream that is ideal for drying and cooling of extruded materials.

To discuss your application and how an EXAIR Super Air Wipe can benefit you extrusion process, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

Cooling Punch Points with a Super Air Knife

A stamping facility had a high speed perforating operation. The idea was to punch holes into a matrix at a fast feed rate.  In their operation, they started to see issues with the punched holes, and they also noticed that the punch points were prematurely failing.  With a tight punch-to-matrix clearance, heat was building up from the friction.  This effect was galling the material and affecting the hole appearance and dimensions.  They also noticed heat damage to the punch points.  They either had to slow their process down, or find a way to cool the punch points.  They contacted EXAIR to see if we could help.

To remove heat, you need to have a fluid moving across the material to carry the heat away. For this customer, the fluid would be air.  Just like a hot cup of coffee, you can cool it by blowing across the top of it.  In this instance, EXAIR can blow a lot of air with using very little amount of compressed air.  Because of the gap opening of the tool die was narrow, I suggested the Super Air Knife.  It has a compact design and can blow nicely between the upper and lower die.  With slight modifications, they were able to mount the Super Air Knives right into the base set.  Because the tool die was a “bowl” type design, I suggested that they should use two pieces of the model 110206 Super Air Knife.  They could mount one to each side to make sure to hit all the punch points.  (Reference the picture below).

Punch Press with a Super Air Knife
Punch Press with a Super Air Knife installed

EXAIR Super Air Knives are the most efficient compressed air knives in the market. It is designed to have a 40:1 amplification ratio.  That means for every one part of compressed air, it will entrain 40 parts of the free ambient air.  As with the coffee reference above, the more air that you can blow, the better the cooling effect.  With the Super Air Knife, we can reach a velocity of 11,800 feet per minute at 80 PSI.  After the customer installed the Super Air Knives, they were able to increase production by 10%.  Also, they found that the punch points were lasting twice as long.  They were so impressed with the effectiveness of the Super Air Knives, they mounted them to all their punch press machines.

Super Air Knife
Super Air Knife

If you find that heat is affecting your process, EXAIR could have a product to help you. We have a variety of efficient air movers to cool your parts.  As for this customer above, we were able to increase production and extend the life of their tools.

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

EXAIR Super Air Knives Improve Process in an Aluminum Rodding Shop

pile-of-product
Piles of material underneath conveyor in aluminum making process

Recently, one of the world’s largest producers of aluminum initiated a study to determine the costs associated with material spillage in their facilities.  The purpose of their internal investigation was to quantify the time, money, and production losses derived from material spillage and accumulation in their rodding shop (the portion of the aluminum making process in which the anode rods are recycled).  Their findings were astounding.

sak-before
Material buildup underneath conveyor in rodding shop

Underneath the conveyors in the rodding shop were mountains of spilled material.  This material would accumulate to dangerous levels, causing safety hazards for workers to potentially slip or trip, interference with conveyor belt operation, an inability to service the conveyors, and a constant cleaning requirement.  Essentially, the accumulation of material would reduce the lifespan of conveyor components while simultaneously preventing maintenance personnel from being able to service the failed components.

failed-roller-1
Failed rollers, pulled from conveyors in the rodding shop

So, the spilled material would be vacuumed from the affected area, conveyor maintenance would be performed, and then the (vicious) cycle would repeat.

Overall, these spills cost over $85,000 per year in cleaning costs (vacuuming spilled material weekly at a cost of $1,650.00), 7100 minutes of unscheduled downtime loss (the process must be stopped during vacuuming and repair to the conveyors), an increased safety risk due to slips and trips on the spilled material, and reduced life of their conveyor belting, rollers, and pulleys due to operating in bath of rubble and dust.

Finding a solution for this problem was no small matter.  This customer needed a permanent and reliable solution to eliminate the mountains of material underneath their conveyors.  And that solution was to install EXAIR Super Air Knives on the underside of the belts, aimed opposite the direction of belt travel, and aimed toward the dust collection system, as shown below.  Before and after photos of the installation are shown below as well.

sak-installed-underneath-belt
An aluminum Super Air Knife (with plumbing kit from EXAIR) installed on the underside of a conveyor.
sak-before
Seven days of accumulation without the Super Air Knife installed
sak-after-pile-was-there-before
Seven days of accumulation with the Super Air Knife installed. Note: the pile in the background was there from the previous week.

The images above show how the Super Air Knives perfectly solve this problem.  They prevent the accumulation of material underneath the conveyors, eliminating $85,000/year in cleaning costs and 7100 minutes of unscheduled downtime, removing the safety and maintenance concern, and adding longevity to the conveyor components.

Cleaning intervals were revised from daily requirements to an interval up to 12 weeks in some locations.  (The shortest interval was revised from daily to every 3 weeks.)

return-roller
No more of these. This is a failed end roller, replaced after only two weeks in service. Lifespan for conveyor components was greatly improved after the installation of Super Air Knives.

So, the burning question is “How much did this solution cost the end user?”

Total costs to implement this solution were $16,000.00.  Based on the cleaning costs alone, the return on investment for this project was under three months.  When the downtime and additional conveyor maintenance is factored in, ROI is realized even faster, perhaps in under two months.

For EXAIR Application Engineers, thoroughly identifying customer problems and integrating an optimal solution is one of our specialties.  In this case we were able to see the benefits our products can have on a single process, saving the customer tens of thousands of dollars per year.

If you have a problem plaguing your facility and would like to discuss potential solutions using EXAIR products, contact one of our Application Engineers.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE