Improved Safety Benefits Employees & the Company

“Safety is Everyone’s Responsibility” is a slogan that companies around the world have adopted.

A refinery that processes palm oil from palm seeds had pipes throughout their facility to transport the oil. They would periodically have to clean the 10” diameter pipes as part of a maintenance program.  To do this, they would use a rubber plunger-like device called a pig to move through the pipe lines.  When they opened the piping system to install the pig, palm oil would leak onto the floor.  In their safety protocol, they would place adsorbent barriers around the spills and use a wet/dry vacuum to pick up the waste oil.  They would discard the liquid in a vat for disposal.  The wet/dry vacuum was limited in size to only hold 5 gallons because the operators would have to lift the container to dump the oil in the vat.  If the oil spills exceeded 5 gallons, then they would have to make multiple trips.  They wanted to get a better system as time was of the essence when you have oil on the floor.

6296 Deluxe RDV System

In speaking about their operations, they were needing to improve on their process and safety. I recommended the model 6296 Deluxe Reversible Drum Vac System.  This system uses a two-way pump and siphon tube that mounts into a 55 gallon drum easily without any modifications.  The pump uses compressed air, not electricity, to quietly generate a vacuum to a level of 96” of water. It does not have any moving parts, no motor or bearings to wear out, so it is very reliable and maintenance free.  The deluxe system comes with our Spill Recovery Kit for complete liquid pickup, a drum dolly, vacuum hose, and tool accessories with a holder.  In replacing their current system with the EXAIR Reversible Drum Vac, they could now vacuum a larger volume of liquid during excessive spillage without stopping.  Once the waste oil was vacuumed and contained, they could then just push their drum to the disposal vat.  With a simple turn of the knob, the two-way pump changes from a vacuum system to dispensing the waste oil into the vat.  This removed the need to lift any containers which could cause back damage to the operator.

Easy to change the operation

Easy to change the operation

As stated in the OSHA website, “Businesses spend $170 billion a year on costs associated with occupational injuries and illnesses — expenditures that come straight out of company profits. But workplaces that establish safety and health management systems can reduce their injury and illness costs by 20 to 40 percent. In today’s business environment, these costs can be the difference between operating in the black and running in the red.” Safety is everyone’s responsibility, and in using EXAIR products, you can do your part like the refinery above.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Choosing the Right Dry Vacuum – Chip Vac or Heavy Duty Dry Vac

A common question we get from our customers is, ‘I need a dry vac, should I use the Chip Vac or Heavy Duty Dry Vac.’  This is very good question, and we will take the time to better understand the application in order to best answer that question.

Both the EXAIR Chip Vac and Heavy Duty Dry Vac are designed to turn an ordinary 5 (Chip Vac only,) 30, 55, or 110 gallon open top drum into a powerful, industrial duty vacuum cleaner. Both are powered by compressed air, and have no moving parts to wear out or break, whereas the typical electrically operated system has motors and impellers that clog and break down quickly.  The Chip Vac and Heavy Duty Dry Vac are also quiet, at half the sound level of electric versions.

The Chip Vac is designed specifically for vacuuming chips. It creates a powerful direct flow that is ideal for metal, wood, and plastic chips.  Because it has a filter bag, in can also handle the occasional dusty material, and keep the surrounding air clean.

If the operation machines different materials, the lid can be removed from one drum and moved to another, to keep the materials separate for easy recycling.

4 R UMAX PL-II V1.4 [3]

The Chip Vac is ideal for vacuuming metal, wood or plastic chips

The Heavy Duty Dry Vac was engineered to vacuum more dry material in less time with less wear. The hardened alloy construction resists premature wear and the increased power makes difficult jobs and harsh environments more easily handled.

110hddvpr_559x447

The 110 Gallon  Heavy Duty Dry Vac provides maximum capacity for spill clean up

The Heavy Duty Dry Vac is ideal for abrasive materials such as steel shot, garnet, metal chips and sand, and is also useful for general purpose applications such as vacuuming floors, machines, work stations and machinery/equipment.

Like the Chip Vac, the Heavy Duty Dry Vac drum lid fits any open top drum, and can be moved from one drum to another facilitating recycling efforts.

Below shows the powerful performance of the Heavy Duty Dry Vac when considering large, heavy material and the increased performance you could expect.

capture

Vacuuming Rate Comparison, for Chip Vac and Heavy Duty Dry Vac

To discuss your application and for help deciding which dry vac would work best, feel free to contact EXAIR and one our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Need an Upgrade? EXAIR has options.

Occasionally we field calls from customers who are currently using an EXAIR product but are looking to “upgrade” to something that might provide just a little bit “extra”. Such was the case recently when I was working with a customer who was currently using our Reversible Drum Vac to clean out their coolant tanks on their milling machines. The RDV was working great in the application but in an effort to gain more floor space, they were now going to store their coolant drums on their mezzanine, located around 10′ above the machining area so they needed something with more power to lift the heavy liquid coolant up to the mezzanine. I promptly suggested our High Lift Reversible Drum Vac. The High Lift Reversible Drum Vac provides up to 15′ of vacuum lift and mounts through the same, 3/4″ NPT threaded hole in the drum lid as their current unit. By purchasing a new High Lift pump unit only, and a 20′ vacuum hose, this customer avoided purchasing a completely new system (they  or other unfamiliar product. They simply replaced the pump unit into the 3/4 NPT bung of the existing drum, and swapped out the hose to meet their existing needs of higher lift.

HLRDV

The High Lift Reversible Drum Vac is designed to fit 30, 55 and 110 gallon, closed head steel drums.

This is just one example how EXAIR continues to offer new products to meet increasing customer demands. In fact, several other products have also been recently expanded or developed to demonstrate this commitment. Here is a short list showcasing some of our newer offerings.

The Chip Trapper System which filters suspended solids in liquid and traps them in a reusable filter bag inside the drum, is also offered in a High Lift version as well, providing the extra vacuum (180″ water column) discussed above, for elevated tanks or below grade sumps.

high-lift-chip-trapper

High Lift Chip Trapper System

We now offer our Heavy Duty Line Vac Air Operated Conveyors in 2.5″ and 3″ sizes with either smooth or NPT threaded ends. The HD Line Vac is constructed of a proprietary hardened alloy construction for superior abrasion resistance and is capable of moving dry material, higher and farther distances.

Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

Our 1/2″ NPT Atomizing Nozzles provide higher flow rates, up to 303 GPH,  with varying spray patterns. Also available with our N0-Drip feature to positively stop the liquid flow when the compressed air supply is shut off.

ef5010ss

EF5010SS 1/2″ NPT External Mix Narrow Angle Flat Fan Pattern Atomizing Nozzle with flows up to 303 GPH.

no-drip

No-Drip Atomizing Nozzle eliminate liquid waste.

The High Velocity Air Jet and Adjustable Air Jet are now available in 303 Stainless Steel for application requiring superior construction where brass may not be suitable.

6013ss

Model # 6013SS Stainless Steel High Velocity Air Jet

 

Stainless Steel Adjustable Air Jet

Model # 6019SS Stainless Steel Adjustable Air Jet

Lastly, we now offer our HD HEPA Vac in a 30 gallon capacity for smaller area, lower scale cleanup for dusty environments.

Heavy Duty HEPA Vac Family

Heavy Duty HEPA Vac Family

All of these products are shipped from stock and can ship same day with orders received by 3:00 PM EST. If you are looking to upgrade your current EXAIR product or with help selecting the best solution, please give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Maintenance Free And Proud Of It

Caller: Do you sell rebuild kits?
Me: Yes, but…why?

This is a WAY oversimplified summary of the start of a popular conversation that an EXAIR Application Engineer might have with a caller looking to restore a particular product to proper operation. Truth is, most of our products have no moving parts, and if you supply them with clean, dry air, they’ll run maintenance free, darn near indefinitely. We’ve documented this in specific cases regarding a Reversible Drum Vac from 1999, a Vortex Tube from 1987, and a Cold Gun from 1985.

Product & year of manufacture, from top left: Reversible Drum Vac (1999,) Cold Gun (1985,) Vortex Tube (1987.) All still performing within factory specifications.

Product & year of manufacture, from top left: Reversible Drum Vac (1999,) Cold Gun (1985,) Vortex Tube (1987.) All still performing within factory specifications.

Caller: So…DO you sell rebuild kits?
Me: Yes, but…only when necessary.

It’s important to note that none of the products mentioned above needed any parts replaced to return to service. Sometimes, a good cleaning is all that’s required. We can help you with a video tutorial if you want to know how to restore a Reversible Drum Vac, an Air Knife, or an Atomizing Spray Nozzle, for instance.  And we’re making new videos all the time for product maintenance, operation, tips & tricks, etc.

Caller (again): So…you DO sell rebuild kits?
Me: Yes, of course!  I mean, who wouldn’t sell rebuild kits for their products?

Take our Safety Air Guns, for example. We offer Service Kits, if the trigger and/or internal valve of a Soft Grip or Heavy Duty Safety Air Gun starts to wear or leak, it’s super easy to replace. We’ve also got replacement springs for the “fail shut” feature of the ball valve of a Super Blast Safety Air Gun. Just about anything else that could be wrong with a Safety Air Gun’s performance can be addressed by cleaning the nozzle.

We also recently added Rebuild Kits for our Atomizing Spray Nozzles to inventory. These contain all of the seals (and moving parts, for the No-Drip models) to restore an EXAIR Spray Nozzle to rated performance.

Keep your EXAIR Atomizing Spray Nozzle (left) in perfect working order with a simple & inexpensive Rebuilt Kit (right of the nozzle.) Contact an Application Engineer to select the one for your product.

For other products, we can also provide replacement gaskets & seals for the Reversible Drum Vac & Chip Trapper products, O-rings for the Line Vacs, Chip Vacs, and Heavy Duty Dry Vacs, new elements for Filter Separators & Oil Removal Filters…just to name a few.

Bottom line: if your EXAIR product isn’t performing the way it used to, give me a call.  It will be my pleasure to help you get it working like new, so that you can continue to get the most out of it.

Russ Bowman
Application Engineer
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EXAIR Chip Vac Removes Swarf and Keeps the Machining Center Running

The word of the day is “swarf”. Swarf is fine chips or filings of stone, metal or other material produced by a machining operation.

A company had four automatic profile cutting machines to cut aluminum stock.  They contacted me for help to improve their operation.  Each machine had a cleated belt conveyor to remove the swarf (or chips) from the cutting process.  Because the swarf was small in size, the chips could get around the edge of the belt and affect the conveying system.  Two of the four conveyors failed, and they wanted to find a better option to remove the swarf and keep the machines running.  They sent me a photo of the type and size of the swarf that was thwarting their conveying system.

Swarf - fine metal chips from machining

Swarf – fine metal chips from machining

EXAIR receives many calls about applications similar to this. I suggested the model 6193 Chip Vac System.  This assembly will fit onto a standard open-top 55 gallon drum which has a much smaller footprint than the conveying system.  The 0.1 micron filter allows for the air to escape and keep the fine particles inside the drum.  For this customer, once the drum was filled with aluminum chips, it was easy to rotate in an empty drum, sending the full drum of material to recycling.  The vacuum generator has no moving parts which makes it quiet, maintenance free, and long lasting.  It also creates a high vacuum level which was very useful when they attached it near the chip collection area.  The Chip Vac System was easy to install and it was very beneficial in keeping the machining area clean and running.

EXAIR Chip Vac

EXAIR Chip Vac

If you find that your chip conveying system is affecting your operations, you should contact an Application Engineer at EXAIR to see if we have a better and more reliable solution to remove your swarf.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Celebrating The Chip Trapper

NFL Football season is officially under way, and my hometown team, the Cincinnati Bengals, are off to a solid start. With less than a minute left in the game on Sunday afternoon, an interception stopped the New York Jets’ final drive, and Who-Dey Nation began to celebrate the win. Some (not me…not as far as you know) may have even celebrated in accordance with a hallowed Bengals tradition:

While I won’t celebrate just ANYTHING (although I do indeed hold prompt service at the deli counter in high regard,) you might get me excited enough to do the Ickey Shuffle if you start talking about how much you like your Chip Trapper.  Just like a caller did this morning.

Now, I’m unabashedly proud of all of our products, so I’m not going to come right out and SAY that I have a favorite any more than I would publicly proclaim one of my children as my favorite.  Although, in all fairness, they’re teenage boys, so at any given time, one of them is quite likely edging out the other on The List.

But back to the Chip Trapper – this morning’s caller just wanted to order some more Filter Bags, but in the midst of our conversation, he started “writing the commercial” for the product:

*It’s extended the life of their coolant – regular removal of solids and particulate contamination means the coolant stays clean & effective.

*It ensures the reliability of the machine – clean coolant doesn’t clog the lines, which WILL wreck the part you’re machining, and probably the tooling too.

*It eliminates odors – OK; nobody ever brags about a “spring fresh” aroma in a machine shop, but bacteria-laden, rancid coolant is the WORST.  Nobody needs to be working around that.  And since that bacteria needs solid surfaces to grow on, filtered coolant is fresh coolant.

*It’s EASY (part 1) – it’ll pump 55 gallons of dirty coolant into the drum in about 90 seconds.  Turn the valve and reverse the direction of the Reversible Drum Vac, and it’ll pump freshly filtered coolant back into the sump just as quickly.

*It’s EASY (part 2) – the Filter Bag holds over 5 gallons (almost 3/4 of a cubic foot) of chips, and the system comes with two of them so you can use one while cleaning out the other.

EXAIR's new Chip Trapper

EXAIR’s Chip Trapper comes in 30, 55, or 110 Gallon Sizes, depending on your needs.

If you’ve got a machine shop and DON’T have a Chip Trapper (yet,) call me; let’s talk.  If you DO have a Chip Trapper and you like it as much as my caller today did, DEFINITELY give me a call.  I might even do the Ickey Shuffle with you.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Reversible Drum Vac Solved a Big Issue that Electric Vacuums Have

Reversible Drum Vac Family

Reversible Drum Vac Family

An industrial contractor used a walk-behind cement saw to cut out and revamp cement floors in commercial buildings. In their operation, they used a lot of water to keep the diamond blades cool and the cement dust down.  A wet/dry vacuum was used for cleanup during and after the sawing operation.   But because of the dust and large amount of use, the electric motors in the wet/dry vac would fail.  The dust would migrate into the bearings of the motor, and you would start to hear a high pitch noise (a mark of the bearings starting to fail).  It wasn’t long, and the vacuum would stop working.

As with many people, they typically start with a lower priced vacuum model from their local hardware store. It was no different with this contractor.  He found out shortly that he was replacing the vacuum units every 4 to 6 weeks.  With the excessive down time and continuously running to the local hardware store, it was becoming too much.  He decided to spend the extra money and get an industrial type vacuum unit.  It had a 30 gallon tank, a drum dolly, and a 2 HP electric industrial motor.  He spent nearly $800.00 on this rugged vacuum, hoping that he would not have to purchase another unit for a while.  Even though the electric motor was heavy duty, it was no match for the cement dust.  This unit stopped working like the others after only six months of use.  After this failure, he decided to search for a better alternative.

When he contacted me about his issues with the short-lived operations of his electric vacuums, I knew EXAIR had a solution. I suggested our model 6396-30, a 30 gallon Premium Reversible Drum Vac System.  The 30 gallon size made it very easy to fit into his work truck and to setup at different locations.  With the Spill Recovery Kit included in this system, it made cleaning up the water/cement mixture quick and efficient.  The EXAIR vacuum generator has no moving parts or bearings to wear.  It is made from stainless steel construction which is very resistant to corrosion, and it is very quiet as it only has a decibel rating of 86 dBA.  For the commercial buildings that did not have compressed air yet, he used a portable compressor to operate his new Reversible Drum Vac.  With clean compressed air, this vacuum will last for many years; not months.

If you find that you are going through your electric vacuums or just would like to reduce the noise levels, EXAIR has a large line of Industrial Housekeeping Products. You can contact an Application Engineer to see if we have the right vacuum product for you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

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