Protect Finishes and Save Liquid with EXAIR No Drip Atomizing Nozzles

A typical “liquid-only” nozzle is capable of producing droplet sizes of 300-4,000 microns. Atomizing Nozzles’ droplet sizes are consistently under 100 microns, and can be as small as 20 microns!

In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water.  You can help ease some of that cost by being more effective in spraying.  The EXAIR Atomizing Nozzles can achieve this objective.  By using compressed air, the liquid can be sheared into small micron-sized droplets.  As a reference, if the diameter of a particle is reduced by one-half, this will multiply the number of droplets by eight.  So, smaller diameter droplets will increase the coverage area and reduce liquid requirement in your application.

EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and Siphon Fed.  We offer a variety of spray patterns and sizes; so, you can accurately target and use the proper amount of liquid in your system.  In this blog, I will narrow my discussion to the No Drip External Mix Atomizing Nozzles.

The No Drip option is offered with all of our Atomizing Nozzles.  This patented design is used to keep the expensive liquid from dripping out of the Atomizing Nozzles during off cycles.  When the compressed air is turned off to the nozzle, a valve inside the body will create a seal on the liquid side.  This No Drip function enhances the External Mix Atomizing Nozzle for intermittent processes as the liquid remains inside the body for quick spraying. With delicate applications, the unwanted drips will not occur to ruin the finish of your product.  Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function.  The External Mix Atomizing Nozzles with the No Drip options can give you the best performance in efficiency, effectiveness, and flexibility without any drips.

No Drip External Mix

To expand on the External Mix Atomizing Nozzle, it atomizes the liquid outside the nozzle.  The air and liquid supply are pressurized and can be controlled independently.  This type of Atomizing Nozzle will allow for higher viscous fluids to be sprayed up to 800 CPS, similar to SAE 40W oil.  Also, with the external mixing, it helps to diminish the drying effects of solutions which will reduce shutdowns for cleaning.  EXAIR manufactures these nozzles with stainless-steel construction making them compatible with many different kinds of liquids.  They are used in many applications like washing, coating, cooling, quenching, and dust control.

Spray nozzles in action.

EXAIR stocks three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT ports; so, you can create a light mist or a monsoon.  The combination of an air cap and a liquid cap controls the spray patterns and liquid flow rates.  These caps are easily interchangeable for each body size to change the spray patterns, control the amount of fluid, and reduce any downtime for cleaning.  The amount of liquid to be applied is easily adjusted by the inlet air pressure and liquid pressure.  So, you can dial in the exact amount of fluid required for your process to stop any waste or excess.

They have a compact design to mount inside tight areas, and we also have mounting brackets for easy attachment and positioning.   If your application needs versatility, fluid savings, and precise coverage; the No Drip External Mix Atomizing Nozzles could be the nozzle for you.  If you have any questions about our Atomizing Nozzles or spraying applications, an Application Engineer at EXAIR will be happy to help you.

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

 

Compressed Air Quality and ISO 8573-1 Purity Classes

Airborne particles surround us everywhere.   In a general work environment, nearly four million particles per cubic foot is floating around us at any given time.  When a compressor compresses this air, the concentration increases substantially.  So, compressed air is not only expensive to make, but very dirty.  As the air exits your air compressor and travels into your pneumatic system, there is so much contamination that the International Standard Organization, ISO, created an Air Quality chart with Purity Classes.

ISO8573-1-2010

This chart is easy to follow and can be found in the ISO8573-1 standard for Air Quality.  It is used to select a cleanliness level for your compressed air system.  The contamination is categorized into three areas; Particles, Water, and Oil (reference above).  A Class is associated with a number for each category ranging from 0 (most stringent) to 9 (most relaxed).  As an example, an Air Quality value of ISO8573-1:2010 [1.2.4] has a Class 1 for Particles, Class 2 for Water, and Class 4 for Oil.  These Class values will show the maximum value in each category.

To define the categories in more detail, I will separate the three to discuss the origins and solutions.

  • Particles: For solid particles, this part comes from many different areas.  The surrounding ambient air that is being drawn into the air compressor is filtered; but the intake filter will only remove large diameter particles.  The smaller diameter particles will go through the filter and into the compressed air system.  Another part is rust particles that occur from steel air pipes and receiver tanks.  Over time, rust will flake off and create particles that can affect pneumatic equipment.  Other particles can come from components inside the air compressor, valves, etc., that wear and breakdown.  In the ISO column for Particles, it is separated into three different micron ranges and concentrations.  The removal of particles from the compressed air is done by traps and compressed air filters.  EXAIR offers two types; Filter Separators with 5-micron filtration and Oil Removal Filters with 0.03-micron filtration.  There are other types of filtration systems depending on your ISO requirement.
  • Water:  Humidity is a natural occurrence as water vapor in the surrounding air.  It can be measured as a dew point temperature.  This is the temperature at which water will condense and make rain.  Inside an air compressor, the air is ‘squeezed”, and the amount of space for water vapor is reduced.  So, it will condense into liquid form as “rain” inside the pipes.  Air that comes out from an air compressor will always be saturated with water.  To remove liquid water, a mechanical device can be used.  Inside a Filter Separator, a centrifugal separator will spin the air and remove the liquid water.  To remove water vapor, a compressed air dryer is required like a refrigerant, desiccant, deliquescent, or membrane type.  Each type will have a dew point range that they can reach.  As an example, a refrigerant type will reduce the dew point near 37 oF (3 oC).  That means that water will not condense until the temperature reaches below 37 oF (3 oC).
  • Oil: This category can be found as a liquid, aerosol or vapor, and it includes more than just oil. It contains small hydrocarbons, CO, CO2, SO2, and NOX.  Oil mainly comes from inside an oil-flooded air compressor.  As the air passes through the compressor, it will pick up remnants of oil aerosols and carry it downstream.  With high temperatures inside the air compressor, some of the oil will vaporize.  Even with oil-less type air compressors, carbon vapor can still be an issue.  Small hydrocarbons can come through the air intake and condense inside the system like water vapor above.  To remove the liquid and aerosol type of oil, Oil Removal Filters can be used.  They are designed to “coalesce” the small particles into larger particles for gravity to remove.  Oil vapor requires an activated carbon to remove.  These types of filter units will adsorb the vapor.  This helps to remove odors as well as dangerous chemical vapors that may be in the compressed air line.

There are a variety of pneumatic systems that use the ISO8573-1 standard.  This will include breathing air operations, food and beverage, pharmaceutical, and the electronic industries.  If you need stringent requirement for your compressed air system, the Air Quality standard should be used by referring to the Class numbers above.  This helps to dictate the types of filtration and air dryers that should be used within your pneumatic system.  If you have any questions about your compressed air system, an Application Engineer at EXAIR can help.

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

 

ISO 8573-1 Chart by Compressed Air Best Practice.

Heavy Duty Air Conveyors Resist Abrasion, Transfer Heavy Materials

Threaded Heavy Duty Family

As an Application Engineer, I get the pleasure to speak to many companies about trying to find a simple, long-lasting, powerful but quiet transfer systems.  They have operators that climb steps to dump bags of material in hoppers above.  Or they need a compact way to remove scrap from their process.  Or they have budgetary constraints to convey material from point A to point B.

If your company had to tackle any of these issues, EXAIR can help you.  We manufacture Air Operated Conveyors that do not have any moving parts, are very compact in design, and have a high throughput capacity.  They can attach easily to standard hoses, pipes, or sanitary flanges.   These inexpensive conveyors are designed to make conveyance safer and ergonomically better for your operators.  EXAIR calls this product line, Line Vac™.

Line Vacs use a small amount of compressed air to generate a vacuum by a Venturi effect.  The unique design generates a high velocity to create a powerful vacuum on one side.  Once the product reaches the throat area of the Line Vac, the compressed air will carry the product the rest of the way.  The product can reach horizontal distances up to 100 feet (30 meters) and vertical heights up to 20 feet (6 meters).  EXAIR manufactures a variety of Line Vacs in different sizes, styles, and materials.  In this blog, I will cover our most powerful and abrasion resistant type, Threaded Heavy Duty Line Vac.

Male NPT Threads make permanent and rigid installation into a piping system a breeze.

Threaded Heavy Duty Line Vacs are designed to convert regular piping into a powerful conveying system.  They range from ¾” NPT to 3” NPT and can connect easily to PVC and steel pipe fittings.  The construction is made from a hardened alloy steel to resist wear from abrasive bulk products like steel parts, sand, glass, ceramic, etc.  The Threaded Heavy Duty Line Vac can create a higher vacuum level to pick up heavier objects as well as conveying larger volume of material.

When purchased as a kit, the Line Vac will come with a filter, regulator, and a mounting bracket.  This adds overall value in mounting, controlling, and protecting the Line Vac for years to come.  This simple device is a great product to use in rugged industrial applications, and with no moving parts, you will not have to worry about any motors or bearings prematurely wearing out.

If you need to convey heavy materials like steel shot or abrasive products, the Heavy Duty Line Vac could be a blessing for you.  Not only can they transfer material safely and quickly, but they also will help ergonomically in saving the backs and knees of your operators.  If you would like to discuss your conveying application further, please contact an Application Engineer at EXAIR.  We may have a solution for you.

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

 

 

EXAIR Around the World

I would like to share a conversation with a company that I visited in Singapore.  They manufactured natural rubber material, and they were having issues with material sticking inside the oven.  In our conversation, they would have to stop the process in order to clean the area near the chopping blades where the rubber material would collect.  The system would have to be shut down for the entire day to clean the oven which lost profit and production yields.

I was familiar with this company because they are global.  I remembered that I helped their American counterpart with the exact same application.  I was able to make a quick recommendation for the same product; two model 110260SSPKI Stainless Steel Super Air Knives.  They purchased and installed the Super Air Knives to generate an air curtain to keep the rubber material from sticking to the wall and forcing it into the grinder below.  This helped them to save a lot of money for unscheduled shutdowns.  If the U.S.A. company was able to share this information, it would have been a great cost savings for the corporation as a whole.

Since the establishment of EXAIR in 1983, customer satisfaction has always been the cornerstone of our business model.   And with that business model, our business continues to grow each year.  Now EXAIR is recognized as a brand of excellence.  We shaped this culture by having great customer service and high-quality products that are safe, effective, and very efficient.  With thousands of products in stock, we are able to ship with over a 99.9% on-time delivery.  As a company, EXAIR offers free expert technical advice and share solutions to pneumatic issues through EXAIR Blogs, Videos, application library, and social media.

In today’s market, many companies are global and have plants and facilities throughout the world.  If details like cost savings, safety, increased productivity, problem solving, and energy efficiency would be shared; it would be very beneficial for everyone.  It can help to grow profits, protect employees, improve throughput and save energy which will help to protect the environment.  Since EXAIR is a leader in these areas with compressed air products, we can help you and your affiliates with pneumatic solutions.

EXAIR sells direct in the U.S.A and Canada, and we have over 50 distributors located throughout the rest of the world.  EXAIR has structured our world-wide presence by country in our International Map located on our website.  It is simple to use.  To find a distributor, click on this link, International.  Fill in your Name, Email, and Country.  We also ask if you would like to receive news about EXAIR products in the future.  You can select “Yes” or “No”.  If you would like to obtain information monthly from EXAIR about new products, special notices, or featured products, then click “Yes”.  And, if we do not have a distributor in your area, EXAIR has an International Department that can assist you directly.

Just like the customer above, if the U.S. manufacturer was able to share the information with their sister company in Singapore, it would have saved them a great deal of grief.  To be more effective and efficient as a global company, there should be communication between associates.  If you or your affiliates use compressed air to cool, dry, clean, convey, vacuum, or remove static electricity, EXAIR can improve your process.  And if you have locations outside of U.S. and Canada, we can still help you.  You can contact us directly or visit our International Map.  You may find someone near you that can speak your language and discuss the values that EXAIR represents.  You will be glad you did.

Welcome to EXAIR.
Bienvenido a EXAIR.
Bienvenue chez EXAIR.
Добро пожаловать на EXAIR.
Witamy w EXAIR.
欢迎来到EXAIR。
Willkommen bei EXAIR.
Tervetuloa EXAIR: iin.
EXAIRへようこそ。
Bem-vindo ao EXAIR.
EXAIR에 오신 것을 환영합니다.
مرحبًا بك في EXAIR.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Generators for the EXAIR Vortex Tubes

Vortex generator

The EXAIR Vortex Tubes use compressed air to generate cold air down to -50 deg. F (-46 deg. C) without any moving parts, freon, or electricity.  By design, it will produce hot air at one end and cold air at the other.  EXAIR offers different cooling capacities ranging from 135 BTU/hr (34 Kcal/hr) to 10,200 BTU/hr (2,570 Kcal/hr).  This cooling phenomenon begins by spinning the air at a high rate of speed inside the Vortex Tube.  The “separation” of temperatures starts at the generator.  In this blog, I will discuss the features of the generator and how our design allows for an efficient way to cool and heat the air flows.

Vortex Family

EXAIR stocks three different sizes of the Vortex Tubes; small, medium, and large.  Each Vortex Tube will use a generator to define the cooling capacity and compressed air usage.  When compressed air enters the Vortex Tube, it will have to pass through the generator first.  The generators are engineered with vane openings to initiate the spinning of the air and to control the amount of air that can pass through it.  As an example, for a medium-sized Vortex Tube, a model 10-R generator will only allow 10 SCFM (283 SLPM) of air at 100 PSIG (6.9 Bar).  While in that same size body, a model 40-R generator will allow 40 SCFM (1,133 SLPM) of air at 100 PSIG (6.9 Bar) to be used.  Precision in the design of the generators is what sets EXAIR apart with efficiency and effectiveness in cooling.

EXAIR Vortex Tube Performance Chart

EXAIR created a chart to show the temperature drop for the cold end and temperature rise for the hot end, relative to the incoming compressed air temperature.  Across the top of the chart, we have Cold Fraction and along the side, we have the inlet air pressure.  The Cold Fraction is the percentage of the inlet air that will blow out the cold end of the Vortex Tube.  This is adjustable with a Hot Exhaust Air Valve at the hot end.

As you can see from the chart, the temperature difference changes as the Cold Fraction and inlet air pressure changes.  You may notice that it is independent of the size of the generator.  So, no matter which size Vortex Tube or generator is used, the temperature drop and rise will follow the chart above.  But just remember, cooling capacity is different than cooling temperature.  At the same settings, a larger generator will give you more mass of air to cool faster.

Now, let’s look inside the Vortex Tube (reference photo above).  As the compressed air passes through the generator, the change in pressure will create a powerful vortex.  This spinning vortex will travel toward one end of the tube where there is an air control valve, or Hot Air Exhaust Valve.  This valve can be adjusted to increase or decrease the amount of hot air that leaves the Vortex Tube.  The remaining part of the air is redirected toward the opposite end as the cold flow, or Cold Fraction.

Now, what separates EXAIR Vortex Tubes from our competitors are the three different styles of generators and two different materials for each size.  These generators are engineered to optimize the compressed air usage across the entire Cold Fraction chart above.  With temperatures above 125 oF (52 oC), EXAIR offers a brass generator for the Vortex Tubes.  The same precision design is applied but for higher ambient temperatures.  With the wide range of Vortex Tubes and generators, we can tackle many types of cooling applications.

If you would like to discuss your cooling requirement with an Application Engineer at EXAIR, we will be happy to help.  This unique phenomenon to generate cold air with no moving, freon, or electricity could be a great product to use in your application.

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

EXAIR Siphon Fed Air Atomizing Nozzles: Overview

In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water.  You can help alleviate some of that cost by being more effective when spraying these liquids.

The EXAIR Atomizing Nozzles can accomplish this by using compressed air to shear the liquid into small micron-sized droplets.  By reducing the diameter of a particle by half, this will multiply the number of droplets by eight.  This will increase the surface area and coverage of the droplets; thus, requiring less material in your application.  EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and the Siphon Fed.  In this blog, I will cover the Siphon Fed Atomizing Nozzles that EXAIR manufactures.

When no liquid pressure is available, the Siphon Fed Atomizing Nozzles will create a vacuum to draw the liquid into the nozzle.  This action is done by the unique design of the air cap.  As the velocity of the air passes through the air cap, a low pressure is created by a venturi.  The Siphon Fed Atomizing Nozzles can draw liquid from a suction height of 36” (91 cm), or it can be gravity fed from 18” (46 cm) away.  They are manufactured from stainless steel for durability and corrosion resistance.  The Siphon Fed models can spray viscous fluids up to 200 centipoise, and are used in many applications like washing, coating, cooling, quenching, and dust control.

EXAIR carries three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT ports; so, you can create a light mist or a monsoon.  The maximum liquid flow rate through each body size is controlled by the air cap and liquid cap.  A unique feature of the EXAIR Atomizing Nozzle is that the caps are easily interchangeable for each body size to modify the spray patterns, control the amount of fluid, and reduce any downtime if cleaning is required.  Here is a video that shows how this can be done:

The amount of liquid to be applied is easily adjusted by the siphon height, the inlet pressure, and the liquid adjusting stem.  So, you can dial in the exact amount of fluid required for your process to eliminate any excess waste. They are very compact and easy to install.  We carry mounting brackets for each size to allow for easy mounting and positioning.   Versatility is very important in saving, applying, and spraying costly fluids; and, the Siphon Fed Atomizing Nozzle has it.

Siphon Fed No Drip Option

To help reduce waste even more, EXAIR has a No Drip option.  This patented design is used to keep the expensive liquid from dripping out of the Atomizing Nozzles.  When the compressed air is turned off, a valve inside the body will create a seal on the liquid side.  For delicate applications, the No Drip options will eliminate unwanted drips that can ruin the finish of your product.  This option also enhances the function of the Siphon Fed Atomizing Nozzle for intermittent processes.  It will keep the liquid inside the body of the nozzle; so, when air pressure is applied, the Atomizing Nozzle will give an instant spray.

The minimum air pressure required to open the No Drip valve is 30 PSIG (2.1 bar) for the ¼” NPT and the ½” NPT port sizes, and 20 PSIG (1.4 bar) for the 1/8” port size.  Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function.  The Siphon Fed Atomizing Nozzle with the No Drip option is compact, efficient, and precise without any drips.

If you need to maximize the liquid dispersion and minimize liquid consumption, the EXAIR Atomizing Nozzles are the products to use.  Instead of researching the requirements for liquid pumps or pressure pots, the Siphon Fed Atomizing Nozzle can draw the liquid through the feed line and start spraying.  It can help reduce the cost of your project as well as save you money on your consumable products.  If you have an application involving liquid spraying, an Application Engineer at EXAIR can help determine the correct model for you.

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

Flat Super Air Nozzles: Overview

EXAIR’s Flat Super Air Nozzles have been blowing away the competition since 2003.

EXAIR manufactures a variety of nozzles that are OSHA safe, high quality, and very efficient.  They are engineered to entrain the “free” ambient air into the air stream to create a powerful force while reducing compressed air usage.  Thus, saving you money.  With a multitude of blow-off applications like clearing small holes to quickly cleaning gantry CNC tables, EXAIR has the nozzles for you.  In this blog, I will discuss the features and benefits of the EXAIR Flat Super Air Nozzles.

The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air.  Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise.  They come in two widths; 1” (25mm) and 2” (51mm).  EXAIR offers a standard Flat Super Air Nozzle and a High Force Flat Super Air Nozzle in two different materials, zinc-aluminum alloy and 316 stainless steel.  And with a metal construction, breakage is not a concern and performance are not sacrificed even in the harshest of environments.  The unique patented shims inside the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function.  First, they come in different thickness to create a wide range of forces.  In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a blast without overusing your air compressor.  The patented design also allows an even flow across the entire width of the air nozzle.  Lastly, they help to entrain the free ambient air; so that less compressed air is required.  The high efficiency design will save you money.  The EXAIR Flat Super Air Nozzles are effective in uniform blowing with safety and efficiency in mind.

To expand more on force adjustments with the Flat Super Air Nozzles, EXAIR has an easy way to change the shim to better suit your application.  You can increase or decrease the force of the nozzle by just removing two screws and changing the thickness of the shim inside.  EXAIR offers a variety pack called a Shim Set to give you a wide range of forces with the nozzles.  For the standard Flat Super Air Nozzle, they come stock with a 0.015” (0.38mm) shim for both the 1” and 2” sizes.  The corresponding Shim Sets will include a 0.005” (0.13mm), 0.010” (0.25mm), and 0.020” (0.51mm) shim.  The High Force Flat Super Air Nozzles will come standard with a 0.025” (0.64mm) shim; and the Shim Set will include a 0.020” (0.51mm) and 0.030” (0.76mm) thick shim.  This is a unique feature as most competitive flat nozzles do not allow you to do this.  The chart below corresponds the appropriate Shim Set to the Flat Super Air Nozzle.

Flat Super Air Nozzle to Shim Set Chart

What can make the Flat Super Air Nozzles even better?  Flexibility.  The Stay Set Hoses can add this for positioning the Flat Super Air Nozzles.  They are designed to manually move the Flat Super Air Nozzle to accurately target the air stream.  They allow the maneuverability to locate the nozzle at different heights or angles; and once positioned, the Stay Set Hose will hold the nozzle in place.  They come in different lengths from 6” (152mm) to 36” (914mm).  We carry two different styles of connections to adapt to any of the Flat Super Air Nozzles.  You can select the different lengths of Stay Set Hoses to the Flat Super Air Nozzle by the model number make-up sheet below.

EXAIR also can offer a Magnetic Base to your Stay Set Hoses and Flat Super Air Nozzles.  The Magnetic Base has a powerful magnet on the bottom to securely attach the blow-off nozzles vertically or horizontally.  This feature is great if you need to move the nozzles to different locations in your application.  EXAIR manufactures a one-outlet and a two-outlet design.  Each outlet has a ¼ turn valve to manually turn on or off the nozzle.  To add this product to the Flat Super Air Nozzle and the Stay Set Hose, you can use the model number make-up sheet below.

With the EXAIR Flat Super Air Nozzles, you can take advantage of the durability, safety, and efficiency for your blow-off devices.  In addition, you can build a system that will best suit your requirements by adding different lengths of Stay Set Hoses and/or Magnetic Bases.  With these combinations grouped in one model number and in stock for quick shipments, it makes it simple to purchase from EXAIR.  And just to let you know, if you are within the U.S. or Canada, they come with a 30-day unconditional guarantee to try them out.  If you need any help with our Flat Super Air Nozzles or how to build an optimum blow-off system, you can speak to an Application Engineer at EXAIR.  We will be happy to assist you.

 

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