EXAIR proves often that we’re able to work with you to create a customized solution that best serves your application. Recently I had the pleasure of working with a customer who wanted a better solution on their tissue paper converting machine. What they currently had was too loud, too inefficient, and they knew there was a better way.
The machine was an old rewinder used to convert webs of tissue paper ranging from 99-115” in width. Installed on the old machine was a 115” drilled pipe with 1/16” drilled holes spaced out every ½” along the length of the pipe. This was using a substantial amount of compressed air and was significantly louder than they would’ve liked. They purchased a new machine that had an EXAIR Super Air Knife already installed and working great, so they reached out to us for some help.
The customer conducted some time studies to determine exactly how much air this application required. The air blast ran for 500 seconds per hour, equating to 8.3min/hr of air usage. The operation runs 24/7, but with time spent doing changeovers the actual run time is closer to 20hrs.
20hrs x 8.2min = 166 min/day of air usage
166min x 365 = 60,590 min per year
A 1/16” unpolished, drilled hole will consume 2.58 SCFM at a pressure of 60 PSIG. With a total of 228 holes across the full pipe, this is quite a bit of compressed air.
2.58 SCFM x 228 = 588 SCFM of compressed air
588 x 60,590 min = 35,626,920 SCF
Considering the lightweight nature of the material, we recommended that the customer use our .001” shim to cut the flow from our stock Super Air Knives to their minimum. We recommended our Model 110054-.001 and Model 110060-.001. At 60 PSIG, a Super Air Knife with .001 shim installed will consume 1.15 SCFM/inch of knife length.
114 x 1.15 SCFM = 131 SCFM of compressed air
131 x 60,590 min = 7,937,290 SCF
Installing the Super Air Knives with .001” shim reduced their air consumption by 77% for a total air savings of 27,689,630 SCF each year. But, what does this mean in terms of money? To determine the cost of compressed air, we use the approximate value of $0.25/1000 SCF.
27,689,630 SCF x $0.25/1000 = $6,922.41
In just one year, on this one single machine, this customer was able to save almost $7k per year. These knives quickly pay for themselves, then begin to contribute to your bottom line. All of this in addition to lowering the sound level and providing a safer working environment for their operators. So how quickly did this customer end up seeing the payback on their two knives?
2022 list prices:
Model 110054-.001 – $1,315.00
Model 110060-.001 – $1,411.00
Total investment: $2,726.00
Based on an operation of 166 min, the customer was saving $18.90 per day. To recoup the initial purchase costs, these would only need to be operated for 145 days. On the 145th day, they’ve already saved enough compressed air to account for their initial costs. Moving forward, that savings does not go away but continues to add to the bottom line.
If you have areas in your facility that are using air inefficiently, contact an EXAIR Application Engineer today.