Author: Jordan T Shouse

How the EXAIR Chip Trapper Transforms Coolant Maintenance

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In todayโ€™s manufacturing environment, efficiency isnโ€™t just about cycle times; itโ€™s about reducing waste, extending fluid life, and minimizing downtime. One of the most overlooked areas of optimization is coolant maintenance. Thatโ€™s where the EXAIR Chip Trapper System comes in. Designed for simplicity and performance, the Chip Trapper offers a smarter way to remove chips, swarf, and sludge from contaminated liquidsโ€”without the headaches of traditional systems.

The Problem with Dirty Coolant

If youโ€™re running CNC machines, lathes, mills, or parts washers, you already know the pain:

  • Coolant becomes contaminated with chips and fines
  • Bacterial growth leads to foul odors
  • Pumps clog and maintenance increases.
  • Fluid replacement costs add up quickly.

In many shops, coolant is replaced far more often than necessaryโ€”simply because thereโ€™s no efficient way to clean it.

What Is the EXAIR Chip Trapper?

The EXAIR Chip Trapper System is a compressed air-powered vacuum system designed to separate solids from liquids quickly and efficiently.

It works by:

  1. Vacuuming contaminated coolant into a drum
  2. Capturing chips and debris in a reusable filter bag
  3. Returning clean liquid back to the machine

This simple but effective process allows you to reuse coolant instead of disposing of it.

See It in Action

Key Features That Set It Apart

1. No Moving Parts = No Downtime

Unlike electric pumps, the Chip Trapper uses compressed airโ€”meaning no motors to clog or wear out.

2. Reusable Filtration System

The filter bag captures solids while allowing clean coolant to pass through, reducing waste and operating costs.

3. Fast Operation

Systems can fill a 55-gallon drum in minutes, dramatically reducing cleanup time.

4. Complete, Ready-to-Use System

Available in 30, 55, or 110-gallon configurations, each unit comes with a drum and all necessary components.

Real-World Applications

The Chip Trapper is ideal for:

  • CNC machines
  • Lathes and mills
  • Parts washers
  • Sumps and tanks
  • Grinding operations

Itโ€™s especially valuable in shops where coolant contamination is frequent and costly.

ROI: Where It Pays Off

The biggest advantage of the Chip Trapper is cost savings. By extending coolant life, shops can:

  • Reduce fluid replacement costs
  • Minimize disposal fees
  • Cut maintenance time
  • Improve machine uptime

In some cases, coolant life can be extended several times over with regular use.

The EXAIR Chip Trapper System isnโ€™t just a cleanup toolโ€”itโ€™s a productivity upgrade. By turning dirty coolant into reusable fluid in minutes, it helps manufacturers cut costs, reduce waste, and keep machines running at peak performance.

If youโ€™re still dumping coolant instead of reclaiming it, it might be time to rethink your process. Give me a call and let’s talk about the application!

Jordanย Shouse
Application Engineer
E:ย JordanShouse@exair.com
O:ย (513)ย 671โ€‘3322
F:ย (513)ย 671โ€‘3363
A:ย 11510ย Goldcoastย Dr Cincinnati OH 45249
www.exair.com

Findย timeย onย myย calendarย byย schedulingย aย meetingย here.

Meet the Next Evolution in Industrial Cleanup: The EasySwitch Wet-Dry Vac โ€” Now Available in ATEX

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In fast-paced industrial environments, cleanup demands can change in seconds. One moment youโ€™re recovering spilled coolant, the next youโ€™re vacuuming metal chips or fine dust. Equipment that canโ€™t keep up slows productivity, increases risk, and drives maintenance costs. Thatโ€™s where the EXAIR EasySwitch Wet-Dry Vac changes the game โ€” and now, with the introduction of the ATEX version, itโ€™s ready for even the most hazardous environments.

One Vacuum. Two Modes. Zero Downtime.

The EasySwitch Wet-Dry Vac was engineered to eliminate one of the most common pain points in industrial housekeeping: switching between wet and dry cleanup.

Traditional vacuums often require time-consuming filter changes, tools, or even separate units. The EasySwitch simplifies this process with a patented, tool-free design that allows operators to transition from liquid recovery to dry debris removal in seconds.

A single latch releases the filter element for quick removal when moving to liquid mode โ€” then reinstalls just as easily for dry applications.

Powered by Air โ€” Not Electricity

Unlike electric shop vacs that rely on motors prone to wear, the EasySwitch operates entirely on compressed air.

This pneumatic design delivers several operational advantages:

  • No motors to clog or burn out
  • Maintenance-free operation
  • Safe for liquid recovery
  • Continuous duty capability
  • Reduced risk of electrical hazards

With no moving parts in the vacuum generator, reliability increases while maintenance requirements drop โ€” a major win for plant managers and maintenance teams alike.

Not that it’s particularly difficult to change the filter in my trusty shop vac, but this is indeed an “Easy Switch”.

Introducing the ATEX EasySwitch: Built for Explosive Atmospheres

For facilities operating in hazardous locations, standard equipment isnโ€™t enough. Thatโ€™s where the ATEX-rated EasySwitch Wet-Dry Vac comes in.

ATEX certification refers to equipment approved for use in potentially explosive atmospheres โ€” environments where flammable gases, vapors, mists, or combustible dust may be present.

These include industries such as:

  • Chemical processing
  • Oil & gas
  • Paint & coatings
  • Food processing (combustible dust)
  • Pharmaceutical manufacturing

The ATEX EasySwitch is engineered to mitigate these risks through explosion-protected design, allowing safe pneumatic vacuum operation in classified hazardous areas.

Because the EasySwitch already operates without electricity, it provides a strong foundation for hazardous-location safety โ€” now enhanced with ATEX compliance for regulated environments.

The Bottom Line

The EasySwitch Wet-Dry Vac redefines industrial cleanup with:

  • Instant wet/dry conversion
  • Tool-free filter changes
  • Pneumatic, maintenance-free operation
  • Powerful vacuum performance

And now, with the ATEX version, it extends those benefits into the most demanding and hazardous work environments.

Whether youโ€™re managing coolant recovery on the shop floor or maintaining compliance in explosive atmospheres, the EasySwitch platform delivers the flexibility, safety, and performance modern industry demands. If you have any questions, please reach out.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

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Efficiency: Air Tools That Pay for Themselves

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In manufacturing, compressed air is often called the โ€œfourth utility.โ€ Like electricity, water, and gas, itโ€™s essential for keeping production running. But unlike the others, compressed air is frequently misapplied, or wasted, making it one of the most expensive utilities in a plant.

The good news is that the right tools can dramatically improve compressed air efficiency. In many cases, they pay for themselves quickly through energy savings, reduced downtime, and improved productivity. Thatโ€™s where EXAIR engineered compressed air products come in.

Letโ€™s look at a few examples of air-powered tools that deliver measurable ROI.

Air Amplifiers: Move More Air with Less Energy

Moving large volumes of air is a common requirement in industrial environmentsโ€”whether for ventilation, drying, cooling, or removing fumes. Traditional compressed air nozzles can consume a lot of air while producing relatively small airflow.

Model 120024 4″ Super Air Amplifiers are commonly used to exhaust welding smoke and fumes.

Air Amplifiers use the Coandฤƒ effect to entrain large volumes of surrounding air, dramatically increasing airflow while minimizing compressed air consumption. In many cases, they can increase airflow up to 25 times the supplied compressed air.

This means you can:

  • Move more air with less compressed air input
  • Reduce overall compressor load
  • Lower energy costs

For applications like ventilating enclosures, exhausting smoke or fumes, and cooling parts, air amplifiers can often replace inefficient open pipe blow offs or multiple air jets.

Super Air Knives: Efficient Blowoff for Drying and Cleaning

Blow off is one of the most commonโ€”and most wastefulโ€”uses of compressed air. Many facilities still rely on drilled pipe or open copper tubing, which wastes enormous amounts of compressed air while generating excessive noise.

Super Air Knives create a laminar sheet of high-velocity air across the entire length of the knife. This provides powerful and uniform blow off while using significantly less compressed air than traditional methods.

Benefits include:

  • Reduced compressed air consumption
  • Uniform drying and cleaning
  • Low noise operation
  • No moving parts and minimal maintenance

Applications range from removing water after washing processes to blowing debris off conveyors, sheets, or molded parts.

Efficiency in compressed air usage isnโ€™t just about saving energyโ€”itโ€™s about improving productivity, reliability, and process performance. When you replace inefficient air practices with engineered solutions, you often gain benefits across the entire operation.

If youโ€™re looking to reduce compressed air waste or improve a blow off, cooling, or static problem, the right air tool may be a small investment with a big return.

And in many cases, itโ€™s an investment that pays for itself.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email

The Hierarchy of Controls and How It Applies to EXAIR Compressed Air Solutions

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In industrial environments, safety teams rely on the Hierarchy of Controls to reduce workplace hazards. Rather than relying on personal protective equipment (PPE), this process prioritizes eliminating risks at their source or engineering them out of the process. For manufacturers, maintenance teams, and engineers, applying the hierarchy of controls can significantly improve safety, reduce downtime, and increase efficiency.

Many compressed air applicationsโ€”blow off, cooling, conveying, and static eliminationโ€”present opportunities to implement safer and more effective solutions using products from EXAIR.

What Is the Hierarchy of Controls?

The Hierarchy of Controls is a widely accepted framework in occupational safety used to minimize or eliminate exposure to hazards. It is commonly promoted by organizations like the Occupational Safety and Health Administration and the National Institute for Occupational Safety and Health.

The hierarchy ranks safety controls from most effective to least effective:

  1. Elimination โ€“ Remove the hazard entirely
  2. Substitution โ€“ Replace the hazard with a safer alternative
  3. Engineering Controls โ€“ Isolate people from the hazard
  4. Administrative Controls โ€“ Change the way people work
  5. Personal Protective Equipment (PPE) โ€“ Protect the worker with gear

While elimination and substitution are ideal, they are not always feasible in manufacturing environments.

Applying the Hierarchy of Controls to Compressed Air Systems

1. Elimination

The most effective control is removing the hazard entirely. In compressed air systems, this can mean eliminating unsafe blow-off methods like open pipes or drilled tubing that create excessive noise, dangerous dead-end pressure, and flying debris. Replacing these setups with engineered solutions from EXAIR Corporation removes many of these hazards while maintaining performance.

2. Substitution

Substitution replaces hazardous equipment or processes with safer alternatives. In many facilities, this involves switching from improvised blow-off devices to engineered products like air nozzles or air knives. These solutions reduce noise, improve airflow efficiency, and significantly lower compressed air consumption.

3. Engineering Controls

Engineering controls isolate workers from hazards through equipment design. Many EXAIR products function as engineering controls by improving safety and reliability in compressed air systems. Devices like safety air nozzles, cabinet coolers, and air knives help control airflow, reduce noise levels, and prevent unsafe pressure conditions.

EXAIR Electronic Flow Control

4. Administrative Controls

Administrative controls focus on improving procedures and training. This includes compressed air safety training, pressure guidelines, and routine system audits. While helpful, these controls rely on human behavior, so they are most effective when combined with engineered solutions.

5. Personal Protective Equipment (PPE)

PPEโ€”such as safety glasses or hearing protectionโ€”is the last line of defense. It protects workers from hazards but does not remove the risk itself. Implementing engineered compressed air solutions can reduce many hazards before PPE becomes necessary.

Compressed air is one of the most widely used utilities in manufacturingโ€”but itโ€™s also one of the most misused. Improper blow off setups, excessive noise, and inefficient airflow can introduce safety hazards and energy waste.

With the right approach and the right equipment, companies can create safer, quieter, and more efficient processesโ€”while maximizing the performance of their compressed air systems.

Solutions from EXAIR, help organizations move up the hierarchy by replacing unsafe methods with engineered products designed specifically for industrial environments.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email

Hierarchy of Controls Image courdsey of CDC.Gov