Author: Neal Raker

Super Air Amplifiers: Smart Ways to Improve Your Processes

Published on by Neal RakerLeave a comment

If you rely on compressed air for blow off, cooling, or ventilation, you already know the challenges: high energy costs, excessive noise, and inconsistent performance. That is where EXAIR’s Super Air Amplifiers can make a measurable difference—helping you move more air, use less compressed air, and solve problems more efficiently.

How Super Air Amplifiers Can Help You

Whether you are trying to improve throughput, reduce costs, or create a safer working environment, Super Air Amplifiers are designed with your goals in mind:

  • Get more airflow from the air you already use
    With amplification ratios up to 25:1, you can turn a small amount of compressed air into a powerful, high-volume airflow—helping you do more without increasing consumption.
  • Reduce noise on your plant floor
    If loud blowoff or open pipes are a concern, these units provide a balanced, laminar airflow that can be up to three times quieter, helping improve working conditions and support OSHA compliance by lowering overall noise within an application.
  • Lower operating costs
    By using compressed air more efficiently, Super Air Amplifiers help cut down on energy waste—especially compared to open tube blowoffs or inefficient nozzles.
  • Minimize maintenance and downtime
    With no moving parts, you do not have to worry about wear, breakdowns, or constant upkeep. Install them and focus on production—not repairs.
  • Adapt to your exact application
    Adjustable shims allow you to fine-tune airflow and force, so whether you need gentle drying or aggressive blowoff, you can dial in the performance you need. Use of a pressure regulator in addition, provides even finer adjustment of force and flow to really dial in exact needs.
  • Install quickly and move easily
    Compact, lightweight design with mounting flange makes Super Air Amplifiers simple to integrate into existing equipment or reposition as your process evolves.

Improve Your Blowoff and Drying – Super Air Amplifiers are built to solve everyday production challenges across a wide range of applications:

If you are struggling with parts that are not drying fast enough or debris that will not clear, Super Air Amplifiers can:

  • Clean chips, coolant, or contaminants from machined parts.
  • Blow away saw dust and chips from wide swaths to keep sensors clear.
  • Dry parts on conveyors without slowing production.
  • Reach complex geometries like channels and blind holes.

In real-world use, manufacturers have combined Super Air Amplifiers with targeted air jets to clean difficult transmission components that other methods could not manage effectively.

Speed Up Your Cooling Process

If hot parts are creating bottlenecks or safety concerns:

  • Cool castings faster without damaging them. Blowing ambient temperature air onto a glowing hot part is the industrial equivalent to blowing on a hot cup of coffee (the temperature differential is already there; the Super Air Amplifier delivers the large volume of cooling airflow to get the job done quickly.
  • Reduce waiting times for operators.
  • Keep production lines moving.

For example, a foundry eliminated delays caused by overheated parts by installing multiple units over a conveyor—allowing workers to handle parts immediately instead of waiting.

Improve Ventilation and Air Movement

If your workspace needs better airflow, the Super Air Amplifier’s Suction or Discharge end can be used effectively to:

  • Move heat away from critical areas.
  • Ventilate confined spaces.
  • Improve comfort and safety for operators.

Solve Unique or Challenging Applications

Super Air Amplifiers are not limited to traditional uses. They have even been used to create instant, high-velocity air blasts for special effects where conventional blowers failed due to noise or slow response. They have also been used in rather hi-tech applications such as protecting lasers and removing microscopic debris from etching operations in the semiconductor industry to produce finer detail and less contamination.

Integration Into Automated Systems

Super Air Amplifiers can be controlled automatically through use of EXAIR’s EFC – Electronic Flow Control System to turn the Super Air Amplifier on and off as needed to further save on compressed air use. It is also possible to control them with a simple, solenoid valve that can be tied into your own control system to provide the same, only when needed effect.

Why This Matters For You

Many facilities rely on makeshift solutions—open pipes, drilled tubing, or oversized blowers—that seem inexpensive upfront but cost more over time in energy, noise, and maintenance. Super Air Amplifiers offer an engineered alternative with performance being paramount to design.

Super Air Amplifiers give you a better alternative by helping you:

  • Use less compressed air while achieving better results.
  • Reduce noise without sacrificing performance.
  • Improve consistency across your process.
  • Eliminate inefficiencies that slow down production.

A Simple Upgrade with Big Impact

If you are looking for a straightforward way to improve your operation—without adding complexity, Super Air Amplifiers offer a proven solution. They help you clean, cool, dry, and ventilate more effectively, all while lowering costs and improving working conditions.

Bottom line: You get more performance from your compressed air system—and fewer headaches from the equipment that relies on it. I would encourage you to reach out to us and allow us to help you determine if Super Air Amplifiers can help you in your applications.

Neal Raker, International Sales / Application Engineering Manager

Extend Refractory Life with an Unusual (and Practical) Cooling Fix

Published on by Neal RakerLeave a comment

How an EXAIR Super Air Amplifier can reduce hot-spot damage and save thousands in unplanned downtime.

Hot spots on refractory walls are common in high-heat operations, but premature refractory failure need not be. If you can quickly pull heat out of a problem area (without touching the lining), you can reduce thermal stress and keep your furnace running longer.

Figure 1. Targeted, non-contact cooling helps stabilize refractory hot spots before they become cracks or spalls.

The problem: localized hot spots

During heat cycles, refractory walls rarely heat perfectly evenly. Burner impingement, scale buildup, airflow changes, and normal process variation can create concentrated hot spots. Left unchecked, these areas run hotter than the surrounding area, accelerating wear that shows up as cracking, spalling, and ultimately downtime.

The solution: EXAIR Super Air Amplifier

A Super Air Amplifier converts a small amount of compressed air into a high-velocity, high-volume stream of ambient air. Aimed at a hot spot, the airflow impinges on the outside surface of the refractory to carry heat away quickly without contacting or mechanically disturbing the lining.

Because cooling is targeted and non-contact, it can reduce peak temperatures and thermal gradients in critical areas. The result: less thermal stress, slower localized erosion, and a better chance of getting maximum life from your refractory lining.

The payoff: more uptime and real savings

Even small gains in living life matter. Extending a campaign by days, or even hours, can help you delay an early reline, reduce emergency maintenance, and keep the furnace in production when it counts.

In many operations, that additional runtime translates into thousands of dollars savedthrough fewer relines, less lost production, and more predictable maintenance planning.

A simple cooling upgrade with a significant impact.
The EXAIR Super Air Amplifier is a dependable, low-maintenance solution for addressing refractory hot spots, protecting your furnace investment, and improving your bottom line. If hot spots are shortening your lining life, it’s worth considering as part of your standard operating response.

Neal Raker, Application Engineering Manager
nealraker@exair.com

Compressed Air Safety in Industrial Environments: Key Risks and Best Practices

Published on by Neal RakerLeave a comment

Compressed air powers tools, equipment, and cleaning processes in many facilities—but it can also cause serious injuries, damage equipment, and disrupt operations when used improperly. Here is a concise look at the main hazards and the practices that reduce risk.

Common compressed air hazards

  • High-pressure injection and flying debris: Air blasts can propel chips and dust into eyes and skin; air can also enter the body through cuts or openings and cause life-threatening injury.
  • Excessive noise: Blow-off and open pipes can exceed safe sound levels, contributing to permanent hearing loss and making communication harder.
  • Whipping hoses and failed fittings: A loose or damaged hose can detach and strike workers with significant force.
  • Contaminants in the air stream: Oil, water, and particulates can affect product quality, degrade tools, and create health risks in certain applications.

OSHA note: blow-off pressure limits

OSHA Standard 1910.242(b) requires compressed air used for cleaning to be reduced to less than 30 PSI at the nozzle when dead-ended (blocked), and to be used with effective chip guarding and appropriate PPE. Meeting this requirement is a baseline for a safe compressed air program.

Many facilities meet these standards by using engineered nozzles and safety air guns (for example, from EXAIR or similar manufacturers) that limit dead-end pressure, reduce noise, and improve blow-off efficiency.

Best practices checklist

  • Use engineered nozzles/air guns: Replace open pipes and improvised nozzles; choose designs that limit dead-end pressure and reduce noise.
  • Control debris: Use chip guards/shields and direct blow-off away from people and walkways.
  • Manage hoses: Secure connections, route hoses to prevent kinks and trip hazards, inspect routinely, and use whip checks where appropriate.
  • Wear the right PPE: Eye protection is essential; add hearing protection where noise is elevated; use gloves/protective clothing as the task requires.
  • Follow safe procedures: Never point compressed air at anyone or use it to clean clothing; depressurize lines before maintenance; train operators and post clear signage.
  • Maintain the system: Keep filters/dryers/lubricators serviced and repair leaks to improve safety and reduce energy waste.

The Bottom Line

Compressed air is essential—but it is not risk-free. When you pair OSHA-aligned pressure control with engineered tools, hose management, PPE, training, and routine maintenance, you reduce injuries, cut down time, and keep operations running safely.

Neal Raker, Application Engineering Manager
nealraker@exair.com

Industrial area with hazardous chemical and high voltage warning signs and two workers in safety gear

UL Hazardous (Classified) Locations Explained: Class, Division, and Group

Published on by Neal RakerLeave a comment
Industrial area with hazardous chemical and high voltage warning signs and two workers in safety gear

When electrical equipment is used around flammable gases, vapors, combustible dust, or ignitable fibers, a single spark or hot surface can be enough to trigger a fire or explosion. That is why equipment for these environments is evaluated and marked for use in specific hazardous (classified) locations. In North America, you will most often see these locations described using the Class / Division / Group system (commonly referenced in NEC Article 500 and reflected in UL/CSA product certifications).

The three parts of a hazardous location rating

  • Class tells you what kind of hazard may be present (gas/vapor, dust, or fibers / flyings).
  • Division tells you how likely that hazard is to be present in an ignitable concentration during normal operation.
  • Group further defines the specific material family (for example, acetylene vs. propane), because different substances ignite differently and produce different explosion pressures.

Step 1: Understand the “Class”

  • Class I: Locations where flammable gases or vapors may be present (for example, areas where solvents, fuels, or certain process gases are managed).
  • Class II: Locations where combustible dust may be present (for example, grain handling, powdered chemicals, plastics, wood, or metal dust processes).
  • Class III: Locations where ignitable fibers or flyings may be present (for example, textile-related fibers). These are typically not in suspension in the air at explosive concentrations, but they can still accumulate and ignite.

Step 2: Understand the “Division”

Division 1 indicates the hazard can exist under normal operating conditions. For example, when a process routinely vents, opens, mixes, transfers, or otherwise releases flammable vapors or gases into the air. It can also apply where ignitable concentrations may exist frequently because of routine maintenance or adjustment activities.

Division 2 indicates the flammable gas/vapor (or combustible dust) is handled or stored in closed systems and is not expected to be present in an ignitable concentration during normal operation. The hazard typically shows up only under abnormal conditions—like a seal failure, a broken fitting, an unexpected spill, or loss of ventilation. Division 2 areas are also commonly found adjacent to Division 1 areas (where a release could migrate).

Step 3: Understand the “Group” (Class I: Groups A, B, C, and D)

Within Class I locations, the “Group” letter helps identify the type of gas or vapor involved. Standards use representative gases to define each group (for example, acetylene for Group A and propane for Group D). Grouping matters because different gases ignite differently and can produce different explosion pressures—so the enclosure, wiring methods, and other protection techniques must match the risk.

GroupWhat it generally includesCommon examples you may see referenced
AAtmospheres containing acetylene.Acetylene processes and storage areas.
BAtmospheres containing hydrogen or gases with similar characteristics.Hydrogen handling, some battery rooms, certain chemical processes (site-specific classification applies).
CAtmospheres containing ethylene, ethyl ether, or similar hazards.Chemical production/processing where these vapors may be present.
DAtmospheres containing propane, gasoline vapors, naphtha, alcohols, acetone, benzene, butane, natural gas, and many other common industrial solvents and fuels.Fuel storage/transfer, paint and solvent handling, many general process areas with common hydrocarbons.
  • Why the groups matter: Groups A and B are generally considered more demanding because the representative gases (acetylene and hydrogen) have ignition and pressure characteristics that require more robust protection methods.
  • How to read “Groups A, B, C, D”: If equipment is marked for Groups A, B, C, and D, it means it is acceptable for use with any of those Class I gas/vapor groups (assuming Class and Division also match). If it is marked for only Groups C, D, then it is not intended for acetylene (A) or hydrogen (B) environments.

Tip: You will sometimes hear “Class I, Div. 1” described as the more demanding environment because ignitable concentrations can be present in day-to-day operation. “Class I, Div. 2” often applies where the hazardous material is normally contained (sealed piping, closed vessels) and only becomes a risk if something goes wrong.

What about dust and fiber? (Class II and Class III)

Class II locations involve combustible dust. Dust hazards can be especially tricky because layers of dust can accumulate on equipment and ignite from heat, and suspended dust can explode if it reaches an ignitable concentration.

  • Class II, Group E: Combustible metal dust (often conductive), such as aluminum, magnesium, and similar materials.
  • Class II, Group F: Carbonaceous dust, such as coal, charcoal, and coke dust.
  • Class II, Group G: Other combustible dusts that are not in Group E or F, such as grain, flour, wood, plastic, and many chemical dusts (exact material and particle properties matter).

Class III locations involve easily ignitable fibers or flyings (think lint-like materials). The risk is typically tied to accumulation near equipment rather than a dust cloud explosion, but the ignition and fire spread risk can still be significant.

How to read a typical marking

Hazardous location markings are shorthand. Here are a few examples of how to interpret them:

  • Class I, Div. 1, Group B: Flammable gas/vapor environment where ignitable concentrations may be present in normal operation; gases similar to hydrogen.
  • Class I, Div. 2, Group D: Flammable gas/vapor environment where ignitable concentrations are not normally present; common hydrocarbons/solvents such as propane or gasoline vapors may be present if something abnormal occurs.
  • Class II, Div. 1, Group F: Combustible dust environment (carbonaceous dust) where hazardous dust may be present in normal operation.

Why is hazardous-location equipment different?

Hazardous-location rated products are designed with one goal: do not let the equipment become an ignition source. In everyday industrial settings, ignition can come from arcing contacts (switches/relays), static discharge, hot motor surfaces, or even a loose connection. Depending on the protection method, hazardous-rated equipment may use sealed or heavy-duty enclosures to help contain an internal ignition, limit the chance of sparks reaching the outside atmosphere, and/or control maximum surface temperature.

Choosing the right equipment (and the right rating)

The key takeaway is that a hazardous location rating is not just a label—it is a safety match between your site’s classified area and how the equipment is designed to prevent ignition. Before specifying or installing a product, confirm the area classification for the exact location (including the Class, Division, and Group) and verify the equipment’s certification and markings.

Quick FAQ

  • What does “C1D1” mean? It is shorthand for Class I, Division 1—a gas/vapor hazardous area where ignitable concentrations can exist during normal operation.
  • Is “explosion-proof” the same thing as hazardous-location rated? People often use the terms interchangeably, but markings matter. Always verify the nameplate matches the required Class / Division / Group (and any other required ratings) for the installation area.
  • Who determines the classification? The classification is based on the process, materials, and ventilation at a specific site and is typically documented by qualified personnel and verified by the authority having jurisdiction (AHJ). These can be local fire marshals, building inspectors, zoning boards. At a state level it can be state fire marshals or health departments, at a federal level it can be OSHA.
  • Why does Group matter if I already know it is Class I? Because acetylene, hydrogen, ethylene, and propane-family vapors do not behave the same. The Group helps ensure the equipment is evaluated for the ignition characteristics of the actual gas/vapor present.

Note: This article is intended as a practical overview. Final hazardous area classification and equipment selection should be performed by qualified personnel and verified with the applicable codes/standards and the authority having jurisdiction (AHJ).

Neal Raker, Application Engineering Manager
nealraker@exair.com