Category: Compressed Air

Vortex Tubes For Spot Cooling Processes

Published on by Al WooffittLeave a comment

EXAIR’s Vortex Tubes are a great product for many cooling applications. When supplied with a clean and moisture-free source of compressed air, they will generate two streams of airflow, one hot and one cold. They are a low-cost and reliable solution, capable of producing temperatures ranging from -50°F to +260°F. We have flow rates from 2 SCFM to 150 SCFM, producing refrigeration over 10,000btu/hr.

We also have several other product lines that are great for cooling, like our Air Knives or Air Amplifiers. So, why would you choose a Vortex Tube? Our Air Knives and Amplifiers cool primarily by moving large volumes of ambient air. If you have a 400°F part that needs cooling to under 100°F, then hitting it with large amounts of 70°F ambient air is going to rapidly bring the temperature down. This does mean that there is a limit to how low of a temperature you can achieve with these products; our Air Knives and Amplifiers won’t be able to cool below ambient temperatures. Our Vortex Tubes, on the other hand, with temperatures as low as -50°F, can provide much more powerful cooling and targeted cooling.

Now you have determined that a Vortex Tube is right for you, you’ll need to decide between our two different series: 32XX and 34XX. The difference between the two model types comes down to the Cold Fraction, which is determined by where the Control Valve is positioned. When you open the Control Valve (by turning it counterclockwise, as shown by the blue arrow in the photo to the right), it decreases the Cold Fraction, which leads to a reduced flow and a significant drop in temperature in the cold air discharge. Conversely, closing the Control Valve (by turning it clockwise, indicated by the red arrow) boosts the cold air flow, but causes a smaller temperature drop. This ability to adjust is crucial for the Vortex Tube’s flexibility.

 You can set the Cold Fraction as low as 20%, which means that a small portion (20% to be precise) of the supply air is sent to the cold end, resulting in a significant temperature drop. On the flip side, you can crank it up to 80%, meaning that most of the supply air heads to the cold end, but the temperature drop won’t be as drastic. Our 34XX Series Vortex Tubes are designed for cold fractions between 20–50 %, while the 32XX Series caters to 50–80 % Cold Fractions.

So how do you select the right model for you? To determine this, you need to know what temperature and flow will best serve your application. For most situations, the ~20°F produced by an 80% cold fraction is sufficiently cold. At this cold fraction, you will get the most flow (80% of the inlet supplied). Applications like welding or brazing benefit from higher flows. When your starting temperature is hundreds of degrees Fahrenheit, there is little difference in blowing -20°F air vs +20°F. What you need is more volume to strip away the heat as quickly as possible. In this instance, a 32XX series is the way to go.

If you need lower flow, or to achieve freezing temperatures, then the 34XX series would be the best choice. A chocolate maker took advantage of the lower flow rates offered by this type of Vortex Tube as they didn’t want the airflow to disturb the surface of the chocolate as it cooled, affecting the finish. The greater temperature drop allowed for rapid cooling without reducing quality.

Vortex Tubes can produce higher levels of noise than our Knives and Amplifiers, so we would always recommend using hot and cold mufflers with them. This will ensure they stay within OSHA sound standards. And just like with all EXAIR products, it’s a good idea to use a pressure regulator with a gauge right where you’re using it. This is especially crucial for Vortex Tubes if you want to get an accurate temperature.

Whatever your cooling application, our Vortex Tubes will likely be able to help. If you would like to discuss it, please give us a call!

Al Wooffitt
Application Engineer

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Week 6 Back to Basics- Control the Pressure

Published on by Brian FarnoLeave a comment

If you’ve been following along with this blog miniseries, you know we’ve reached the final step in the Six Steps to Optimizing Your Compressed Air System. Each step so far has built toward this moment—and today we add the last piece of the puzzle.

The final step is simple but powerful: control the air pressure at the point of use to minimize consumption.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

This is done by installing one of our pressure regulators, available in multiple pipe sizes and flow capacities. A small change in pressure makes a big impact. For example, reducing operating pressure from 100 PSIG to 80 PSIG lowers energy use by nearly 20%. In many cases, operations can run at even lower pressures, unlocking even greater savings.

This reduction in energy use is also coupled with the fact that pressure regulators make any compressed air-operated tool infinitely adjustable. Not all applications require the full output force or RPM, or conveying rate that can be achieved at full line pressure with a compressed air-operated product. And so the humble pressure regulator enables this ability for energy savings and control that is on par with any electrical control for voltage or even frequency. Pressure regulators also facilitate our working mantra to use the least amount of pressure and volume necessary to accommodate the application objectives.

All of our regulators are standard stock items, which means they can ship the same day if ordered by 2:00 P.M. Eastern Time. Plus, with 2D and 3D CAD models available through our CAD Library, you can design your entire compressed air system virtually before making a single cut in pipe.

This step, combined with the previous five, gives you a complete roadmap to compressed air optimization. From measuring usage and fixing leaks, to implementing engineered solutions, automating control, using intermediate storage, and now regulating pressure—EXAIR is here to help make the process straightforward and effective.

As always, if you’d like to discuss your application or explore how we can help you optimize your compressed air system, feel free to reach out.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Looking Back with Gratitude, Looking Ahead with Confidence

Published on by Kirk EdwardsLeave a comment

As we close out the year, it’s a good moment to pause and reflect on what this past year has meant for our company and the people who make it possible.

This was not an easy year. We asked a lot of our teams as EXAIR and BETE continued to integrate. We looked for new and better ways to bring our brands to market and worked hard to remain focused on what we do best—serving customers, building high-quality products, and being a great place to work. That balance is never simple, especially in a challenging manufacturing environment, but meaningful progress was made.

Across both EXAIR and BETE in every department, the dedication, collaboration, and professionalism of our employees made that progress possible. Much of that work happened behind the scenes, often under pressure, and it deserves to be recognized. Thank you for showing up, supporting one another, and staying focused on doing the job right.

These companies have exceptional values, and it begins with a focus on people – employees, customers, and vendors. That people-focused initiative also impacts our respective communities. One of the most substantial synergies between EXAIR and BETE is our focus on community. Both organizations contribute significantly by organizing food drives, donating to homeless shelters and transitional housing organizations, purchasing holiday gifts for those in need, and holding clothing drives. BETE provides the time and place for one of the largest, if not the largest, Trunk or Treats in Greenfield, MA. The list goes on, and I am very grateful to work with such community-minded folks.

We’re also deeply grateful to our customers and vendors. To our customers—thank you for trusting us, partnering with us, and challenging us to be better. Your feedback, loyalty, and collaboration continue to shape how we innovate and grow. To our vendors and partners—your reliability, expertise, and commitment have been critical in helping us deliver for our customers, especially in a year that tested supply chains and resources across the industry.

This year also marked an important milestone: BETE celebrated 75 years of history and spray nozzle expertise! EXAIR celebrated 42 years in business. That kind of longevity doesn’t happen by chance. It’s built through adaptability, strong relationships, and people who are willing to evolve while staying true to core values.

As we look ahead, we’re excited about what’s next. With new roles, newly formed teams, and continued alignment across the organization, we’re laying the groundwork for the future. The foundation is strong, the team is strong, and we’re positioned to move forward with confidence.

To our employees, customers, and partners — thank you for being part of our journey. We wish you a safe, restful, and joyful holiday season, and a healthy, prosperous New Year. We look forward to what we’ll accomplish together in the year ahead.

With gratitude,
Kirk Edwards, President

Super Air Knife Shim Sets

Published on by jasonkirbyLeave a comment

EXAIR’s Super Air Knife stands out as a premier solution for reducing both compressed air consumption and noise levels when compared to traditional blowoff techniques. This innovative product is offered in a variety of lengths, ranging from 3 inches to 108 inches, and is constructed from materials such as Aluminum, 303 Stainless Steel, 316 Stainless Steel, and PVDF, making it suitable for corrosive environments. Remarkably, even when operating at high pressures of 80 psig, the Super Air Knife maintains a sound level of only 69 dBA for most applications, ensuring a quieter working environment. The design of the Super Air Knife allows it to entrain air from the surrounding atmosphere at an impressive ratio of 40:1, which significantly enhances its force and airflow capabilities. Furthermore, these air knives comply with or surpass OSHA’s stringent standards for maximum dead-end pressure and noise levels, making them a safe and efficient choice for various industrial applications.

Super Air Knife with Shim Set

The Super Air Knife offers exceptional versatility in adjusting both force and airflow, allowing for precise control tailored to specific applications. When initially purchased, the Super Air Knife is equipped with a .002” thick shim, which establishes the gap between the knife’s body and cap, thereby regulating the volume of compressed air that can pass through its meticulously designed slotted orifice. To enhance its functionality, EXAIR provides a shim set as an accessory for the Super Air Knife. This set includes plastic shims of varying thicknesses—.001”, .003”, and .004”—for aluminum models, enabling users to decrease airflow and force by utilizing the .001” shim or to increase them by opting for a thicker shim. For the stainless steel and PVDF variants, the shim set comprises three .002” shims, with stainless steel shims specifically designed for the stainless models and a PTFE shim for the PVDF. Notably, these shims can be stacked to create a larger air gap, which significantly impacts performance; however, it is crucial to recognize that a larger gap results in increased air consumption. For instance, installing a .004” shim will effectively double the force, flow, and air consumption compared to the standard .002” shim, making it essential for users to carefully consider their requirements when adjusting the Super Air Knife’s settings.

To achieve precise control over the force and airflow of your Super Air Knife, in addition to the various shims available for coarse adjustments, utilizing a pressure regulator is an effective strategy. This device allows you to meticulously adjust the input pressure supplied to the Super Air Knife, which significantly influences both the force and flow characteristics. For instance, operating at a pressure of 40 psig results in a consumption of 1.7 SCFM per inch while delivering a force of 1.1 oz per inch. Conversely, increasing the pressure to 80 psig raises the consumption to 2.9 SCFM per inch and enhances the force output to 2.5 oz per inch. EXAIR provides a range of pressure regulators in different sizes, ensuring compatibility with all models of Super Air Knives, from the compact 3-inch versions to the larger 108-inch variants.

 If you have any questions about the Super Air Knife shim sets, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk