Author: John Ball

The Wide World of Safety Air Guns and Nozzles

Published on by John BallLeave a comment

Have you just glanced around a manufacturing plant? You usually always see either the “curly” yellow hose or a red rubber hose with an air gun attached to it. They hang at work stations, machines, packaging areas, and even in obscure places. The reason that I bring this up is for safety reasons.

Unsafe Air Gun

Recently we had a medium-sized manufacturing plant that was audited by OSHA. One of the first violations that OSHA found was with their compressed air guns with the typical brass pipe with the hole going through the side (one of the most typical types of nozzle). It violated code 29 CFR 1910.65(a) for maximum allowable noise exposure. The company had to make a choice to either purchase hearing protection for the operators or to find an alternative product. They contacted us because we could reduce their noise level. I suggested a Super Air Nozzle, model 1100, for their application. When they attached our Super Air Nozzle to their air gun, they quickly heard the difference between the noise levels. With the added benefits of good quality, high force, and meeting all the safety requirements, they decided to purchase the nozzles with our Safety Air Guns. They ordered 90 pieces of our Soft Grip Safety Air Gun with Chip Shield, model 1210-CS. This took care of the OSHA violation, and the operators were very happy with the product.

Unsafe Nozzle

Another company was using compressed air with a ¼ turn valve attached to a 36” (91 cm) copper tubing. They used this device to reach into areas to blow off chips. The Safety Compliance Officer was familiar with dead-end pressure (OSHA 29CFR 1910.242(b)). It states that compressed air can enter the blood stream through the skin at pressures above 30 psig (2 bar). To keep his workers safe, he mandated a maximum pressure of 30 psig (2 bar). This increased the cleanup time for an operator as the force was reduced greatly. The Safety Compliance Officer contacted us about our Safety Air Guns. I explained that with our nozzles, they are engineered to operate at higher pressures and still be below the dead-end pressure requirement of 30 psig (2 bar). With our design, it keeps the surface of your skin from blocking the air openings, unlike the copper tubing. They ordered 25 pieces of our Heavy Duty Safety Air Gun with a 36” (91 cm) extension and Chip Shield, model 1310-36-CS. The operators were happy with the durability of the gun and with the ability to increase the air pressure for faster cleaning. The Safety Compliance Officer was happy to meet the OSHA standard and to keep his workers safe.

EXAIR offers a variety of different types of nozzles and Safety Air Guns to meet the requirements of your applications. All of our nozzles are safe, quiet, and powerful. We offer them in different materials, from aluminum/zinc, stainless steel, and PEEK. They are designed to entrain ambient air to save compressed air and money. As a note, an air gun is only as good as the nozzle it is using. Many air guns come with a very inexpensive brand of nozzle. They are typically very loud and very inefficient. I always like to use the analogy of a paint sprayer. No matter how good the spray gun is, if you have a poor nozzle, you will end up with many flaws in your paint. The same can be said with compressed air guns.

To keep your company compliant and safe, you can always contact an Application Engineer to help pick the correct product for you.  From now until the end of September 2026, with qualified purchases, EXAIR will be giving away a model 6013SS Stainless Steel Air Jet, a $185.00 value, with a purchase of our Safety Air Guns, including the VariBlast Precision, VariBlast Compact, Soft Grip, Heavy Duty, and TurboBlast Safety Air Guns.  We are promoting the importance of safety in the workplaces.

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

Remove Manual Labor with Air Operated Conveyors

Published on by John BallLeave a comment
EXAIR Line Vacs: For bulk material conveyance through lines from 3/8″ to 6″, in aluminum, 303SS, 316SS, or abrasion resistant hardened alloy, available from stock with the widest variety of connections in the industry.

If you’re performing any type of manual transfer of raw material in your processes, it might be time to take a closer look at EXAIR Air Operated Conveyors, or Line Vacs. The Line Vacs are designed as an ideal solution for the transfer of bulk materials from one point to another. They have no moving parts to wear; they are very compact and easy to install; and they remove safety concerns. I will cover the many selections that EXAIR currently offers.

The Line Vac can move large volumes of material over long distances with just a small amount of compressed air. The compressed air is injected through directed holes that produce a vacuum on one end and high-volume output flows on the other. The Line Vacs are manufactured in several different materials, sizes, and with a few different options for connection style. Adjusting the flow of material is extremely simple and can be controlled by regulating the air pressure upstream of the Line Vac.

Line Vacs can convey many things.

Standard Line Vacs are offered with a smooth inlet/outlet designed to be used with any smooth-bore conveyance hose. These Line Vacs are offered in aluminum sizes from 3/8” (10 mm) up to 5” (127 mm), and in 303 and 316 stainless steel from 3/8” (10 mm) up to 3” (76 mm). Clear PVC conveyance hoses are available for 3/8” (10 mm) up to 3” (76 mm) I.D. from stock in 10’ (3 m) increments up to 50’ (15 m) in length.

EXAIR's Threaded Line Vac Family

If you’d rather use rigid pipe, Threaded Line Vacs are also available directly from stock. With identical performance to the standard Line Vac, the Threaded Line Vacs are offered with NPT threads on both the inlet/outlet in sizes ranging from 3/8” NPT to 3” NPT in aluminum, 303, or 316 stainless steel.

For higher conveyance rates and abrasive materials, EXAIR offers Heavy Duty Line Vacs that are constructed from a hardened alloy steel. The Heavy Duty Line Vacs are offered with both smooth and threaded connection styles from ¾” (19 mm) up to 3” (76 mm). The Heavy Duty Line Vacs are ideal for media that is abrasive in nature or for applications requiring higher conveyance rates over longer distances.

The Ultra Duty Line Vacs are designed to handle the conveyance of extremely abrasive materials. The bodies are made from the same material as our Heavy Duty Line Vacs, but we added a ceramic insert. The overall length is a bit longer to accommodate this insert, but the flow rate, distance, and conveyance rates are the same. This ceramic insert is placed where the conveying material hits the surface on the exhaust side, making it more durable and longer lasting. We currently offer them in 1 ¼”, 1 ½”, and 2” for hose connections.

For applications where you only need to convey small volumes over short distances or particularly lightweight materials, our Light Duty Line Vacs would be an ideal solution. The Light Duty Line Vac is available in sizes ranging from ¾” (19 mm) to 6” (152mm) and consumes less compressed air than the standard and heavy-duty versions. This style of Line Vac is only offered in aluminum construction and for use with a smooth-bore hose.

EXAIR Sanitary Flange Line Vacs come in four popular sizes, and are ideal for applications in the food and pharmaceutical industries…and others (read on!)

Last, but certainly not least, are the Sanitary Flange Line Vacs. The Sanitary Flange Line Vacs are the best method for conveying materials in systems that require frequent or mandatory cleaning. Utilizing ISO 2852 compatible clamp-style sanitary flanges, they can be easily removed from the system for periodic sanitization. These are offered in sizes ranging from 1-1/2” (38mm) up to 3” (76mm) in 316SS construction from stock.  They are ideal for applications in the food and pharmaceutical industries.

If none of these stock Line Vacs suit your process, we may still have an option!! Custom units are available. We can vary the styles of flanges, mix the inlet and outlet connections, and we’ll even manufacture the Line Vacs in special materials. At EXAIR, we take pride in offering custom solutions for customers that may require something just a little different from what is readily available on the shelf.

If there’s a process in your facility that could benefit from a product like the EXAIR Line Vac, act fast! Now through October 31st, you’ll receive a FREE 1104 Super Air Nozzle, a $95.00 value, as a promotion with a purchase of any EXAIR Line Vacs only for qualified orders. If you need help with your application, EXAIR has Application Engineers to help you out.

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

EXAIR is Offering a Promotional Item With Purchase of a Safety Air Gun. 

Published on by John BallLeave a comment

From August 1st to September 30th, 2026, with qualified purchases, EXAIR will be giving away a model 6013SS Stainless Steel Air Jet, a $185.00 value, with a purchase of our Safety Air Guns, including the VariBlast Precision, VariBlast Compact, Soft Grip, Heavy Duty, and TurboBlast Safety Air Guns.  We are promoting the importance of safety in the workplace with the EXAIR Safety Air Guns. 

Compressed air guns are one of the most commonly used pneumatic products in manufacturing plants.  They are used at workstations to blow off debris and clean parts and tools.  Because of the large quantities that are used in a plant, they are the most targeted by OSHA (Occupational Safety and Health Administration).  The majority of the common brands of air guns fail to comply with two common violations, rule 29CFR 1910.95(a) for noise levels and rule 29CFR 1910.242(b) for dead-end pressure.  The reason for this is due to the type of nozzle that comes with the compressed air gun.  OSHA fines can be very expensive, and you can alleviate these penalties by purchasing an EXAIR Safety Air Gun.  Safety is everyone’s responsibility: management, the HSE department (Health and Safety Engineer), supervisors, and even the operators. 

With EXAIR Safety Air Guns, we supply an efficient, effective, and, most importantly, safe air nozzle with all of our air guns.  They are CE Compliant and exceed the OSHA sound level and dead-end pressure requirements, even above 30 PSIG (2 bar).  With substandard air guns, the operators will have to listen to loud noises all day or wear hearing protection.  And for the dead-end pressure, the EXAIR nozzles are engineered to not allow the operator to completely block the end of the nozzle with their hand or skin.  This is very important because if the pressure exceeds 30 PSIG, air can penetrate the skin and cause an air embolism.  With our design, the compressed air is able to escape, and the pressure against the skin will not exceed 30 PSIG, even with the compressed air pressure set at 100 PSIG.  Safety is a major concern for all of our customers and a priority for EXAIR in manufacturing our products. 

As I mentioned above, the nozzles are one of the most significant parts of making a compressed air gun safe and OSHA compliant.  Combining our engineered nozzles with a quality air gun makes the EXAIR Safety Air Guns one of the best products in the market.  We currently have six different styles; the VariBlast Precision, VariBlast Compact, Soft Grip, Heavy Duty, Super Blast, and TurboBlast Safety Air Guns.  These Safety Air Guns are ergonomically designed to comfortably fit in your hand, and they come with quality trigger mechanisms and a durable valve assembly.  The VariBlast Precision Safety Air Guns are great for tight spaces and clearing out small holes.  The VariBlast Compact Safety Air Guns have a cast aluminum body for rugged use with our smaller air nozzles.  The Soft Grip Safety Air Guns provide extra comfort for long, extended uses, and the Heavy Duty Safety Air Guns are rugged, heavy-duty industrial air guns with nozzles for larger forces.  The Super Blast and TurboBlast Safety Air Guns use our largest nozzles for cleaning large areas quickly.  In combination with the EXAIR nozzles, the Safety Air Guns can offer another important attribute; we can save you money!!!  Compressed air is very expensive to make, and with our Safety Air Guns, we use less compressed air but still create a strong blowing force.  We do this by entraining the free ambient air into the air stream.  If you increase the mass of air at the target, it will give you a hard-hitting force to remove debris from surfaces or clean tools and holes.  The amplification ratio can be as high as 25 to 1.  That means that for every one part of compressed air that it uses, the EXAIR Nozzles will entrain 25 parts of free ambient air.  This will add mass to the airstream to give a powerful impact.  Also, the payback period for using an EXAIR Nozzle with our Safety Air Guns can be within weeks due to the savings in electrical costs from your air compressor.  With EXAIR products, we were able to partner with Energy Star and power facilities.  For the amount of energy saved, some power companies offer rebates for using EXAIR products.     

A substandard blow-off gun is unsafe, loud, and wasteful.  EXAIR Safety Air Guns can help improve these situations.  They are OSHA compliant, very safe, and very quiet.  They use less compressed air, which saves you money.  And with a variety of different nozzles, they can better fit your application to decrease downtime.  In the U.S., EXAIR offers a 30-day unconditional guarantee on our cataloged items so you can try them out.  You can see for yourself how effective these compressed air guns can be.  And for a short while, you can receive a promotional gift. If you need help matching the best Safety Air Gun to your application, you can contact an Application Engineer. Remember, safety is everyone’s responsibility.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Resources for Finding the Right Cabinet Cooler System

Published on by John BallLeave a comment
From right to left: Small NEMA 12, Large NEMA 12, Large NEMA 4X

During the warmer weather, electrical panels will start to feel the “heat.”  Freon-based coolers can be less effective in higher ambient conditions; and opening the electrical panels to have a fan blowing air inside creates a dangerous hazard.  To reduce loss in production and premature equipment failures, it is important to keep electrical components cool.  The EXAIR Cabinet Cooler Systems are an easy choice for consistent, long-lasting results. 

Cabinet Coolers are powered by Vortex technology, which uses compressed air to generate cold air flow.  They do not have any moving parts to wear.  They do not require any Freon or a refrigerant compressor that can fail.  They require very little to no maintenance to keep them operating for a long time.  EXAIR offers a variety of types and cooling capacities to work inside some of the toughest of conditions.  We range from 275 to 5,600 BTU/hr (80 – 1641 Watts) of cooling power.  They are easy to install, and EXAIR has several ways that can help you start using our Cabinet Cooler Systems. 

At the start, we do have a Cabinet Cooler Sizing Guide to help determine the total heat load.  This can be sent to us for calculations and recommendations.  We also have a Cabinet Cooler System Calculator on our website if you wish to tackle this yourself. 

EXAIR does an excellent job of helping our customers purchase a Cabinet Cooler System.  We use multiple methods to make sure that you are getting the correct information and the best out of our system.  So, if it is your first time ordering a system, here are some areas to help you quickly and easily install your new unit. 

We have our Installation Guides on our website for instructions and troubleshooting.  If you are more visual, like I am, we also have informal videos to give some tips and tricks.  Here is a list: 

How to install a Cold Air Distribution Kit

How to install Side Mount Kit

The Electronic Temperature Controller upgrade

Using the Cabinet Cooler Sizing Guide

Measuring internal and external air temperatures

Installing the Dual Hardware Kit for Dual Cabinet Coolers

Installing NEMA 4/4X Cabinet Coolers

Connecting the Thermostat to the Solenoid Valve

Resetting the thermostat

If you still have any questions, you can reach us by phone at 800-903-9247 or contact us through Chat.  An Application Engineer is waiting to help you.  For our U.S. customers from now until the end of August 2026 with qualified purchases, you will receive an AC Sensor for free, a $77.50 value, as a promotional item.  As I mentioned above, EXAIR has a number of ways to assist you from start to finish.

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