Memorial Day 2017

We’re in the home stretch now…mere hours away from Memorial Day weekend, or, as I call it, the Official Start Of Summer™.  EXAIR Corporation will be closed on Monday for this occasion. To make good use of this time off, I have three cookouts planned: one at the neighbors’, one at the in-laws’, and the third is self-inflicted.

As much as I like my neighbors and my in-laws (really,) I’m expecting that third one to be my favorite, even considering that I’m the one that has to clean up after it. Why, you may ask? Because we’re going to make s’mores. If you don’t know what s’mores are, I have two thoughts: 1) You’re killing me, and 2) Watch this RIGHT NOW (it’ll make you better understand my first thought too):

Whatever our plans, Monday culminates the celebration of this long weekend…Memorial Day. In the midst of our celebration and activities (or lack thereof – I’m all for some relaxation too,) I encourage you, dear reader, to remember the reason that this day was consecrated.

It was thirteen years ago last month that my wife called me at work to tell me the news that our neighbor’s son had been captured by hostile forces in Iraq.  By the time I got home, yellow ribbons were everywhere…trees, mailboxes, front doors, windows…all in support and hope for Matt Maupin.

Four years later was when the next Memorial Day took on an even more united meaning for our small town, when Matt’s family got the word that he had, in fact, been killed in service of his country.  I still see his father around town, and the grief has spurred determination to make something greater come from the remembrance of his son’s sacrifice.   The Yellow Ribbon Support Center:

*Sends care packages to military individuals serving in harm’s way.

*Hosts an annual “Let Us Never Forget” Scholarship dinner to honor local fallen heroes.  Over half a million dollars worth of scholarships have been awarded to date in remembrance & honor.

*Sends & supports speakers at schools, public events, gatherings, etc. to share the stories of our troops’ heroism.

The Yellow Ribbon Support Center is one of many organizations that could use your help, if you’re so inclined to find one, wherever you may be.  I still think, too, that every one of our fallen heroes, and their families, will want you to have an enjoyable holiday weekend.  It’s been paid for dearly.

Russ Bowman
Application Engineer
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Reduce, Reuse, Recycle

I think we have all heard the mantra Reduce, Reuse, Recycle – a phrase that is thought to have originated back in 70’s when environmental protection became a governmental policy.

We at EXAIR can help your company follow this important principle and help to keep your costs down as well.

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Reduce – Reduce the number of times you change out your coolant, reduce your wastewater. Our Reversible Drum VAcs and Chip Trappers help keep your coolant clean by providing a simple and effective method to remove and/or strain your coolant.

Also, remember this – they are VERY hard to break or ruin. If you have one of our liquid handling Reversible Drum Vacs or Chip Trapper units, and the performance isn’t quite as you remember it to be, give us a call.   We can help to trouble shoot and narrow in on the root cause.  Most of the time, it is a simple fix, such as a air leak or a change to the air supply system that has caused a drop in performance. If we have eliminated all of those possible causes, we can offer the RDVREFURB option. Simply send in your Reversible Drum Vac pump unit, and we will do a free evaluation. Then we’ll let you know what we find, and provide a quote for the repair.  The repair typically involves a thorough cleaning, replacement of a few basic parts, and then setting and testing to original factory specification.  Because the unit has no moving parts, there isn’t much that can break down or go wrong.  Don’t throw away that unit, REDUCE the amount of waste you create.

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Reuse – Maybe you have a Super Air Knife in storage that is not in use, and you come up with a need, but the Knife doesn’t quite match the application.  We can provide new custom shim to change the air flow pattern.  Perhaps you have a 24″ Super Air Knife, but the new application requires only 18″ of airflow.  You can send the knife in and we can clean it up and install a new custom shim to provide the exact airflow pattern that meets your requirements.  Or, we can send the new shim directly to you for your team to install. Don’t let the unused product lie around, REUSE it for another process or application.

Super Air Knife

Recycle – If for what ever reason a product has been deemed to be no-longer viable and cannot be reused, the time comes to dispose of it.  We hope that you would take the time to recycle it properly. With materials of construction including brass, aluminum and type 303 and type 316 stainless steels, most EXAIR products can be RECYCLED as common metals and you may even get a little money back!

To discuss your processes and how an EXAIR Intelligent Compressed Air Product can provide a beneficial service, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Photo Credit – “Recycling” by Andy Arthur is licensed under CC BY 2.0

EXAIR 2″ Flat Super Air Nozzles – Little Things That Make a Big Difference

EXAIR 2″ Flat Super Air Nozzle vs. other nozzles

I recently purchased a dart board to hang on the wall in my basement.  The dart board had a nice wood case with doors.  It also had some beautiful woodwork engraved along the outside edges.  When it arrived, I was so excited I decided to put it on the wall right then.  The wood case had four predefined holes that were 16” apart (to fit onto studs).  I got my tape measure, determined the correct height, and marked the points onto the studs.  As I ran the screw into the wall, I was about halfway into the stud, and the head of the screw broke.  That is correct!!!  It twisted right off the shank.  I was not happy.  I spent good money on a very nice dart board, and the screws were low quality and not tempered correctly.  The screws are only a fraction of the cost of the dart board, but they created a huge headache.  Now, I had to get the screw out and find new better quality screws to continue the process.

As an International Application Engineer for EXAIR, I have been to many facilities throughout the world with large automation systems inside their manufacturing plants.  I always wondered how much money was needed for the capital purchase to get a system created, assembled, and operational.  On many occasions when the customers brought me to their problem areas, I would see the flat plastic “duck-foot” nozzles.  They would be broken, ineffective, and loud.  They were looking for a recommendation to replace these plastic nozzles.  I know that their automation system cost much more than my dart board; but, I can relate to their headaches.

When you have an automated system that costs thousands or hundreds of thousands of dollars, the last thing you want is for nozzles that cost pennies compared to the full system to cause you headaches and problems.  EXAIR has effectively addressed this issue with the model 1122/1122SS 2” Flat Super Air Nozzles.  They are made either from zinc aluminum or stainless steel, not plastic.  This makes them very strong and durable.  With its unique design, they utilize shims which can be easily changed for different force requirements.  For stronger blowing applications, EXAIR also offers this same design in a high power version, model HP1125/HP1125SS.

This makes the 2″ Flat Super Air Nozzle very versatile as you can purchase shim sets with different thickness in your kit.  Now you have more flexibility to “dial” in the correct performance for your application.  Another feature is the ability to draw in large amounts of ambient air to make them very quiet and efficient.  So, it will actually save you money by using less compressed air.  The sound level is only 77 dBA for the model 1122/1122SS, so it is not a noise nuisance.  They are OSHA compliant with noise level, 29CFR1910.95a, and  for dead-end pressure, 20CFR1910.242b.

Since the plastic nozzles break easily, they become very loud and unsafe for workers as they will not meet the OSHA standard.  If you need a durable, versatile, efficient, OSHA safe type of nozzle that will last a long time, the 2″ Flat Super Air Nozzle is an easy choice over the plastic types of nozzles.  If you need help with mounting or positioning the nozzles, we have a line of accessories that can help.  We offer the Stay Set Hose, Magnetic Base, and Swivel Fittings to make it easy to mount and direct the nozzle for optimum performance.

2″ Flat Super Air Nozzle

If you have an automated system that is being contracted or if you are a machine builder, you will want to consider the EXAIR brand for your blow-off, cooling, and coating applications. With the overall cost of the system, you would not want to use poor quality plastic nozzles to save a couple of dollars.  In the long run, it will actually cost you more with loss of production, very loud noises, and an unsafe work environment.  I may have only broken one screw in hanging a dart board due to poor quality, but I can also relate to the unhappy feeling you get when your system is not performing because of low quality nozzles.   If you would like to try out the EXAIR Flat Super Air Nozzles against a plastic nozzle, you can request an Application Engineer to help.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Replacing Blowers with Super Air Knives

Chain conveyor application in need of a blow off solution

The image above shows a chain conveyor with coated handles travelling along a production line. At this stage in their production, these handles have just left a washing station and need to be dried.  In order to finalize the drying process, some form of blow off is needed.

The existing blow off solution which could not effectively remove the water.

The existing blow off setup is shown above. This system utilizes two blower driven air knives to remove any excess water from the handles, but it is proving to be ineffective due to the turbulent nature of the airstream from a blower.  To combat this ineffectiveness, this production facility has placed an employee in front of the existing setup, using a compressed air blow off as a pretreatment procedure.

Personnel were added to this stage of production to provide a pre-blow off treatment.

Having a line operator stationed at this point was undesirable for this customer.  What this application needed was an efficient, productive, and repeatable blow off solution that would eliminate the need for redundant personnel at this stage of production and make the process fully automated. That solution was the EXAIR Super Air Knife.

By utilizing Super Air Knives, this customer was able to create an even and laminar sheet of air to dry these handles. The smooth profile of the airflow allows maximum velocity to be maintained at a further distance from the knife than the existing setup.  This translates to higher force at further distances, which in turn translates to proper part blow off and full automation of the process (the line worker was removed from the application), thus saving cost and eliminating an unnecessary safety risk.

With a required blow off width of ~40” in this application, using (2) model 110042 42” Aluminum Super Air Knives was a perfect fit. If you have a similar, redundant blow off operation in place and would like to make it more effective in terms of results and costs, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

E-Vac for Epoxy Recycling

Recently, a manufacturer of custom magnetics called in about a special application. In the manufacturing of certain electronic systems, a very expensive, thick epoxy glue is used. They were exploring ways to be able to collect the excess after application.  They had used a system in the past and were looking to replicate it.  The previous system had an old boxy vacuum generator, and they asked us if we could provide a vacuum source that matched the performance specifications but in a more compact design.  After researching the specifications and a comprehensive comparison, we could offer the EXAIR model 810013 Inline E-Vac, generating up to 27 ” Hg of vacuum.  A basic sketch of the design concept is shown below-

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By using the model 810013 to create a vacuum within the chamber, a strong suction can be generated at the tube inlet, strong enough to draw in the excess epoxy. The glue can be collected in the chamber for recycling and reuse, and because of the design, the glue does not pass through the E-Vac and cause any issues with build up or blockage that would hinder the performance, leading to the need to clean the unit.

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The Many Sizes of E-Vac Models Available

EXAIR manufactures E-Vac’s for both porous and non-porous applications, as well as a line of Adjustable E-Vac Generators.  Smallest units use only 1.5 SCFM of 80 PSIG compressed air and the largest Adjustable E-Vac unit can pull 81 SCFM of air at open draw and 15″ Hg vacuum level setting.  With a wide range of sizes and types, there is a model available to meet your vacuum generation needs.

As a side note – the EXAIR Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper, and High Lift Chip Trapper all use this same basic principle of applying a vacuum to a chamber, but on a much larger scale, to turn a 5, 30, 55 or 110 gallon drum into an industrial liquid vacuum system.  The vacuum generating unit is of a different design, made specifically for the Industrial Housekeeping Products.

To discuss your process and how an EXAIR Intelligent Compressed Air Product can solve your toughest application issues, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Beat the Heat with EXAIR Cabinet Coolers!

As we begin to approach the heat of summer in the northern hemisphere, we begin to break out the flip-flops, swimsuits, and warm weather attire. If you’re not a fan of the warmer temperatures, this may not be your favorite time of year. For me, I can’t wait to spend some time outdoors and enjoy all of the activities that summer has to offer. Whether you like the heat or not one thing is certain, the electrical enclosures within your facility most certainly do not.

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EXAIR’s Cabinet Cooler Systems were designed specifically to rectify these issues within your facility. Utilizing Vortex Tube technology, the Cabinet Cooler produces cold air from an ordinary supply of compressed air. This cold air keeps the enclosure free of debris and moisture and is easily installed in minutes through a standard electrical knockout. Here is a short video that shows just how simple it really is. The Cabinet Cooler Systems are available with Nema 12 (IP54) ratings and are also available in Aluminum, 303 Stainless Steel, and 316 Stainless Steel construction for Nema 4 (IP66) rated enclosures. For systems that are not able to be mounted on top of the cabinet, we also have Side Mount Kits available in Aluminum, 303 Stainless, and 316 Stainless.

These systems are available with cooling capacities of anywhere from 275-5,600 Btu/hr. To make things much easier for you, we offer a Cabinet Cooler Sizing Guide that will allow us to recommend the most suitable model for your cabinet. With a few quick measurements, we’ll be able to determine the exact heat load that we’ll need to dissipate and offer you a quick and easy solution. If you’re experiencing heat related issues somewhere within your facility or remember the troubles that they caused you last year, contact an Application Engineer today and we’ll see to it that this summer your cabinets remain cool!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Solving Static Problem in PET Plastic Thermoforming Application

PET plastic entering thermoforming machine to make cups

The image above shows a PET plastic sheet which is fed into a thermoforming machine. During thermoforming the plastic is made into drinking cups.  But, if the plastic enters the thermoforming machine with static present, the forming process cannot occur properly which results in defects.

The company in charge of thermoforming these cups reached out to the Application Engineering department at EXAIR in search of a solution to their problem. They had considered using Ion Bars, but were unsure if Ion Bars were the right solution.  So, we examined the process and the variables at play to determine the best path forward to remove this static.

The static in this application was present throughout the travel of the plastic sheet into the thermoforming machine. At EXAIR we always recommend to install any static eliminating solution at the last possible point before the static is causing a process disturbance, to ensure no static is regenerated.  Yes, a static charge has the potential to regenerate with friction, spearation or even simple contact with another surface. In the above example separation from the roll and friction upon the additional rollers could be a source of static. This meant finding a way to eliminate the static just prior to the sheet entering the thermoforming machine.

As it turns out, the thermoforming in this application can occur between 180-260°F, and this heat permeates from the machine to the area immediately outside of the plastic feed entrance. So, placing Ion Bars just outside of the machine, while potentially possible, would place them near temperatures at the high end of their operating temperature limits (maximum temperature for an EXAIR Ion Bar is 165°F).

However, just a couple of feet away from the machine this temperature dissipates significantly. So, if we could find a way to mount our solution 2-3 feet away and effectively eliminate static, we would have a viable solution.

That solution came in the form of Super Ion Air Knives. The Super Ion Air Knives provide the same static eliminating capabilities of an Ion Bar, but with an added benefit of transferring the static eliminating ions via a smooth and laminar air profile.  This allows for us to mount the Super Ion Air Knives a few feet away from the machine entrance, but to still effectively eliminate static.  At a distance of 12” away, the Super Ion Air Knife can eliminate a 5kV static charge in 0.18 seconds at an operating pressure of 80 PSIG, and in 0.60 seconds at an operating pressure of 5 PSIG.

Based on the width of 486mm, this customer opted for (2) 18” Super Ion Air Knives, model 111018, and (1) 230VAC power supply with (2) outlets, model 7907. By installing one Super Ion Air Knife on top of the plastic sheet, and one on the bottom, the static problem in this application is solved.

If you have an application in need of a static solution, contact an EXAIR Application Engineer. We’re here to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR.com

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