Adjustability=Flexibility=Wide Ranging Performance

Recently, I moved into a new house, and it didn’t have bathroom vent fans.  In order to prevent mold and mildew growth from the humid shower air; we decided to install them ourselves.  Going to the local home goods store, we were faced with a wall of options, with factors such as noise level, CFM rating and of course price.  Going over the myriad of possibilities was headache inducing and of course, the bathroom size was borderline between a small and mid-size unit. The decision came down to – pay more and oversize it or risk installing an undersized unit.  If only they made a unit to cover a wide variety of conditions.

Here at EXAIR, we make many types of Intelligent Compressed Air Products.  Many times, when we are talking to customers, the right size or performance needed isn’t quite clear.  Fortunately, many of the products we make are flexible, and allow for adjustability and increased range of performance to best match the specific need of the application.

For example, The Super Air Knives and Super Air Wipes have available Shim Sets to increase or decrease the air gap and change the force and flow.  The shims are easily installed, and come in a wide choice of sizes. Super Air Knives are available, from stock, in aluminum, 303SS, 316SS, and PVDF. Super Air Wipes are made from aluminum or 303 SS.

The Super Air Amplifiers also have available patented Shim Sets to fix the air flow at a predetermined setting. Adjustable Air Amplifiers have an infinitely adjustable air gap which can easily be set to match the application needs if a predetermined flow is not preferred. Adjustable Air Amplifiers also have a smaller footprint than Super Air Amplifiers and can also use the aforementioned shims to preset the air flow in applications where space is limited. These are available in 303 stainless steel and aluminum. We also have a high temperature option.

adjustable Air Amplifier

Adjustable Air Amplifier

Within our already enormous and flexible Air Nozzles & Jets product line, the Flat Super Air Nozzles have available Shim Sets to provide the ability to adjust the force and flow for blowoff or cleaning operation.  The model 1009 Adjustable Air Nozzle has an adjustable gap setting, allowing you to “tune in” the force and flow to meet the application requirement.  Also, the Adjustable Air Jet provides an adjustable gap setting to control the air flow performance. Flexibility also comes from the available materials of zinc/aluminum, aluminum, 303SS, 316SS and PEEK thermoplastic.

For vacuum generation, the Adjustable E-Vac allows for the vacuum and flow rate to be easily adjusted.  With a simple turn of the unit, the vacuum and flow levels can be changed to overcome porosity and increase or decrease the lifting power.

Adjustable EVac

Adjustable E-Vac

There are several other Intelligent Compressed Air Products that EXAIR manufactures that offer the adjustability and flexibility, such as Vortex Tubes and Adjustable Spot Coolers.

If only EXAIR manufactured bathroom fans, I could have ensured making the right choice and be able to match the performance to exactly meet my application needs.

Brian Bergmann
Application Engineer
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Custom, Flanged Air Amplifier Solves a Fume Evacuation Problem

We blog about this topic quite a bit, and almost every section of our catalog has a page set aside just for special / custom product configurations that have been created by request from many of our customers.

This is the latest and greatest special that I have seen roll through the production area here at EXAIR.   This is a special 4″ 303 Stainless Steel Adjustable Air Amplifier with a 4″ Tri-Clamp flange on the discharge side and a 6″ Tri-Clamp flange on the suction side of the amplifier.


This had been an ongoing project with the customer that started with them testing a stock Adjustable Air Amplifier in the application to ensure that the performance would meet their needs.  The application was to boost a low flowing fume exhaust that was causing slow downs in their production line.  Fans and other traditional methods would require maintenance and would wear out.  The stock Adj. Air Amplifiers exceeded their performance needs but did not easily mount into their duct work because they used all standard size tri-clamp fitting in the ducting, so the next step was to see if we could manufacture a Special Adjustable Air Amplifier just for their needs.  The dimensions of the existing Adjustable Air Amplifier came close enough we were able to easily create a Flanged Adjsutable Air Amplifier that would clamp straight into their existing duct work, exceed their performance expectations, help their process, and be ready to ship within a very reasonable lead time.

Like we have said before, if a stock, cataloged, product doesn’t fit your application exactly, contact us and let us find a way to customize and fit the need.

Brian Farno
Application Engineer Manager


Don’t Cry, EXAIR Air Amplifiers Will Help Remove the Fumes

Bitumen is a black viscous product that is used in asphalt, road surfacing, and roofing materials. Much of this product is moved by either railcars or tractor trailers to other industries.  Some precautions are needed when handling this product as the fumes can irritate the eyes, throat, and nose.

Fumes coming out of hatch below platform

Fumes coming out of hatch below platform


A plant that manufactures bitumen contacted EXAIR to see if we had a product that could improve their existing system. They were using a 6” (15 cm) venturi type air mover that was large and cumbersome.  It had a funnel that extended from the outlet by 4 feet (1.2m), and it weighed over 22 lbs (10 Kg.)  The air consumption of this unit was 81 SCFM (2,294 SLPM) of compressed air at 80 PSIG (5.5 bar).  They had to maneuver this heavy device by hand around an elevated platform.  The platform was designed with two smaller platforms that are positioned over the vehicles that they are filled for transport. One platform extended over a rail for railcars and the other platform extended over a driveway for tankards.  The air mover had to be moved and positioned near the filling areas to capture the fumes.  It was heavy, awkward, and in the way.

Their filling procedure was to place the air mover near the opening of the hatch to remove the irritating fumes away from the operators. The filling pipe was 4 inch (10cm) in diameter, and it was spring assisted for easy positioning.  Depending on the vehicle type, they would open a hatch ranging from 12 inches (30.5cm) to 16 inches (40.6cm) in diameter to fill.  The operator would then position the air mover near the opening, insert the fill pipe, and start filling.  The air mover was turned on to draw the vapor coming out of the hatch.   Because of its weight and size, the air mover had to be positioned on the platform at the edge of the hatch opening.  This was not optimum as some of the fumes could still escape at the farthest point away from the air mover.  Once the railcar or tanker was filled, they would move everything to the opposite platform to fill the next vehicle. Because of the design of the platforms and the size and weight of the air mover, there was a high possibility for personnel to become injured from the re-positioning process.  The customer wanted a more effective and ergonomic solution.

Railcar Filling Area

           Railcar Filling Area

The customer added some additional details about his operation. Because bitumen is a tar-like substance, it sticks and gets on everything, they would place dirty parts in an oven to melt the bitumen off the surfaces.  With this high temperature requirement and the size of the opening of the hatches that had to be covered, I suggested a 4 inch (10cm), Stainless Steel Adjustable Air Amplifier, model 6034.

EXAIR Air Amplifiers, have a large amplification ratio (the ratio between the amount of ambient air being moved compared to the amount of compressed air used).  The suggested model, is set for a 24:1 amplification ratio.  This helps greatly to draw in the fumes and smoke in the surrounding area to increase overall effectiveness and to reduce compressed air consumption.  With the size and weight of the EXAIR Adjustable Air Amplifier being much smaller than their present solution, they could mount it directly onto the side of the spring-assisted pipe used to fill the tankers with the product.  (The weight of the model 6034 is only 9 lbs. (4.1 Kg))  This was a major ergonomic success.  They did not have to worry about their operators hurting themselves moving a big, heavy, air mover, and it allowed the mouth of the Air Amplifier to be positioned right over the opening of the hatch.  This helped to catch all the fumes.  As a bonus, the model 6034 consumes only 50 SCFM (1,416 SLPM) of compressed air at 80 PSIG (5.5 bar).  The Adjustable Air Amplifier allowed for a reduction of 38% in compressed air usage when compared to the old method.  By switching to the EXAIR Air Amplifier, it saved them time, pain, money, and tears from eye irritation.

EXAIR Adjustable Air Amplifier

EXAIR’s Adjustable Air Amplifier

If you have an application where smoke and fumes are a nuisance,  Air Amplifiers are a great way to pack a lot of power into a small space for a variety of blowing and venting applications.

John Ball, Application Engineer
Twitter: @EXAIR_jb

Super Air Amplifier Removes Unwanted Scrap Material


EXAIR Super Air Amplifier used for scrap material removal

A few months ago I wrote a blog about using a Super Air Amplifier to remove film from an application workspace and direct it to a waste container.  Earlier this week I had a different end user contact me about a very similar application.


An image of the complete setup in this application

In this application the Super Air Amplifiers are used in an automotive manufacturing facility to direct scrap material from car doors into the large bags below each station.  The scrap material is lightweight and proves to be problematic if not fed into a contained system.


The bags where the scrap material is collected

This particular customer was in need of some assistance to duplicate their existing setup, shown in the photos above, into four more workstations.  So, they reached out to us to confirm the model number of the units (which have been “working perfectly”) based on dimensions.

Snip of dims

Dimensions of the units in place; used to determine model number

Using the provided dimensions I was able to confirm the model number is 120022, our 2” Super Air Amplifier.  After confirming this I was able to provide a quotation for the requested Super Air Amplifiers, available to ship from stock.

If you have a similar application or think an EXAIR product may be able to help solve an application problem in your facility, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer

Use The Force…Or Not…It’s Up To You, Really

The month of May, in 1977, was a great time to be ten years old. I was finishing up my fifth grade year, a pivotal one, thanks to Miss Walker, who ended up being my favorite teacher ever. She had a pet rat named A.J. that we took turns taking home for the weekend. She rewarded us for class performance by taking us outside to play softball on warm & sunny spring afternoons. I trace my love for math (and hence, my inspiration for a career in engineering) to the excitement she instilled in me for the subject…I was among the first to master the multiplication tables.

And then there was Star Wars. There were commercials for the movie and the toys and the merchandise on TV; I swear they ran every five minutes. A fast food chain released a series of posters (free with purchase) and every time a new one came out, Miss Walker promptly hung it on the classroom wall. None of us, her included, could hardly wait until the premiere. I could go on (and on and on and on,) but suffice it to say (for the purposes of this blog,) I’ve been a BIG fan ever since.

Which brings us to today…opening day for “Star Wars, Episode VII: The Force Awakens.” The first time, by the way, a Star Wars movie hasn’t premiered in the month of May, but I digress. The 10 year old inside me wants to go see it RIGHT NOW, but the grownup I have to be has a company Christmas party, two Boy Scout events, and a pre-holiday “honey-do” list to attend to first.

Of course, the “other” epic space movie series couldn’t resist launching THEIR new trailer this week…

All this talk about The Force (capital “F”) and the fact that I write this blog on company time has me thinking about compressed air applications that involve force (lower case “f”) and how using force (unlike “The Force”) is not always prudent.

This is the case in just about any blow off application that uses air under pressure. Open ended copper tubing, drilled pipes, etc., are common and easy ways to discharge compressed air for debris removal, drying, or cooling a part. But the fact is, they waste a LOT of the energy devoted to compressing the air by simply turning it into brute force and noise.

This is where EXAIR Intelligent Compressed Air Products(r) come in: by using the energy of the compressed air to entrain air from the surrounding environment, the total air flow is amplified, resulting in a high velocity blast, at minimal consumption. No; it doesn’t have the same amount of force as an open ended discharge device, but most blow off applications don’t need all that much force anyway.

Of course, there ARE situations where you need to use the force, and we’ve got efficient and OSHA compliant ways to do that too: additional shims in Air Knives, Air Wipes & Air Amplifiers, or larger Super Air Nozzles.

“A long time ago, in a galaxy far, far away,” the continuing theme of the Star Wars saga is to use The Force properly. For the past 32 years, the continuing theme at EXAIR is to help you use the force (of your compressed air) properly. Let me know how we can help.

May The Force be with us all…this weekend, and always.

Russ Bowman
Application Engineer
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The Time When The Only Thing Better Than An EXAIR Product…

…was another EXAIR product. And actually, it happened twice, just today:

  • An insulation manufacturer was using an open pipe blow off to push air into a five foot wide “blanket” of their product to uniformly flatten it, and blow stray fibers out and into a vacuum system for recycling. They tried a Super Air Knife, which blew the stray fibers out just fine, but didn’t produce the flatness they desired, even with additional shims installed. They then experimented with a manifold system, using a series of Model 1104 High Force 3/8 NPT Super Air Nozzles, which provided the force required to blow the loose fibers out, and to produce the uniform material thickness. With a sound level of only 82dBA (which you won’t find ANYWHERE ELSE from a device that delivers 1.9 lbs of force,) they’ve also made the area much quieter.
Definitely try a Super Air Knife first, but if the job calls for high force, Super Air Nozzles can be easily fitted into a pipe manifold like this.

Definitely try a Super Air Knife first, but if the job calls for high force, Super Air Nozzles can be easily fitted into a pipe manifold like this.

  • A major producer of adhesive labels and specialty packaging had been using our Line Vacs extensively for scrap trim removal. They tried them on a new application where the trim was very lightweight. I’ve written before about When You Can Use An Air Amplifier, or A Line Vac, or…Either? – and this was again the case. They tried a couple of Adjustable Air Amplifiers: a Model 6044 4″ unit for the larger pieces, and a series of Model 6043 3″ units to gather in the rest, as the product traversed the production line.

Normally, we like to reserve our bragging on EXAIR products to how much better they’ll perform than the competition’s.  Which we do regularly, and we’ve got the data & experience to back it up.  But, with such a diverse product line, there are going to be situations – like these – where more than one product might fit the bill.  If this is the case, give us a call; we’re here to help you get the most out of your compressed air usage – whichever EXAIR product that may be!

Russ Bowman
Application Engineer
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Cooling a Flue Stack with Air Amplifiers

In some cities when you look along the skyline, you see exhaust stacks bellowing out plumes of smoke. I never paid much attention to the structure except that they were tall and in some cases very wide. I received a call from a customer that had a flue stack that exhausts hot gas in their petroleum process. They had an issue with hotspots in the wall of their stack. The customer need to cool the hotspots and decided to contact EXAIR.

Flue Stack

Flue Stack

His stack had a diameter of 6 foot (1.8 meters), and the hotspots were reaching a temperature of 750 deg. F (400 deg. C). This was too hot, and it could cause premature issues with fatiguing of the structure of the stack. He wanted to reduce the temperature to 400 deg. F (204 deg. C) to keep the stack from warping or degrading. Together, we were able to create a solution using our stainless steel Adjustable Air Amplifiers.

Adjustable Air Amplifier

Adjustable Air Amplifier

The customer was able to create a stainless steel circular manifold to mount 40 pieces of the model 6032 around the circumference. This manifold ring would be mounted around the stack near the hotspot. With the high amplification ratio associated with the Air Amplifiers, it can move a large volume of cooler ambient air along the hotspot of the stack. In keeping the stack cool, he could continue operations and reduce his worry for untimely shut-downs and costly maintenance.

Whenever you have something hot and you need to cool it down, the Air Amplifiers could be the solution for you. If you would like to speak to an Application Engineer about your cooling application, you can contact us at EXAIR at 800-903-9247.


John Ball
Application Engineer
Twitter: @exair_jb


“Stack” image courtesy of paulgalbraithCreative Comment License

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