I recently worked with a customer who was looking to improve the cleaning process on the inside of one of their screw augers. They were currently using a couple of 1/4″ pipes as air wands to clean the left over powder on the auger blades and direct it toward a chute at the bottom which fed into another auger used for recovery. While the setup worked somewhat, they were concerned with the amount of air they were using as well as the OSHA safety concerns associated to using open ended pipes and excessive noise levels.
The customer was able to send a sketch of their current setup and after some further conversations, I recommended our Model # 1122 2″ Flat Super Air Nozzle and our Model # 9053 1/4″ NPT Swivel Fitting. The 2″ Flat Super Air Nozzle produces a 2″ wide, high velocity laminar airflow and uses only 21.8 SCFM (80 PSIG) while maintaining a low sound level of only 77 dBA. The Swivel Fitting allows for 50 degrees of movement, so they can achieve the best angle to direct the air to the critical areas.
All of our Air Nozzles are engineered to meet or exceed OSHA Standard 1910.24(b) for 30 PSIG dead end pressure, they cannot be dead-ended, there is always a path for the air to safely exit so the outlet pressure will never reach 30 PSIG. In addition, our products are going to meet the OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels as well.
If you are looking to reduce air consumption and noise while improving operator safety, give us a call at 800-903-9247 for assistance.
A metal cutting facility would cut pieces of aluminum extrusions, bars and cylinders to specific lengths as requested by their customers. They used a variety of different types of cutting equipment depending on the size and profile, but every cutting machine would use coolant. At the end of the cutting process, they would run the parts through a washing system to remove any coolant and then through an inkjet marking system. They would print the corresponding tag information on the top of each product.
The surface had to be dry or the ink would run and become illegible. To try and speed up the drying process, they attached four soft copper tubes to blow compressed air along the top of the parts. They flattened the ends slightly to give a wider blowing area as well as to direct the air into the T-slots of the extrusions. The customer liked the flexibility of the copper tubes as they would need to change the position often to fit the appropriate size and profile.
The problem that they had with their setup was that the blowing was too loud and it used a large amount of compressed air. They found EXAIR which looked to have a better solution to blow off the water from the product.
The customer gave some additional details on their process. They could cut a wide range of diameters from 2 inches (51 mm) to 12 inches (305 mm) within their bar and cylinder stock. They also would cut square and rectangular extrusions that had a variety of profiles and dimensions. They requested a flexible product that could conform to the different sizes and types and also be adjusted manually for optimum blowing positions.
EXAIR offers a great product line that would fit their requirements for this application, the Blowoff Systems. With their requested specifications, the flat blowing pattern and flexibility, it directed me to the model 1122-9412 Blowoff Kit. This kit comes with a Magnetic Base, Flat Super Air Nozzles, and flexible Stay Set Hoses. The model 1122-9412 has two 2” Flat Super Air Nozzles which will give a wide blowing area.
The Magnetic Base contains two outlets with shut off valves on each port to allow for an easy way to turn off a nozzle when not needed for the smaller products. Between the Magnetic Base and the 2” Flat Super Air Nozzle, a 12” (305mm) long Stay Set Hoses connects them together which will allow for precise blowing and maneuverability.
By installing two pieces of the model 1122-9412 to his system, the customer was able to remove the four pieces of the copper tubing which were loud and inefficient. The noise level dropped to 77 dBA with the 2” Flat Super Air Nozzles which was a relief, and they realized that the air compressor was working less. By adding the Blowoff Kits to their system, they now had a flexible, efficient and effective way in drying the products prior to printing.
With the customer above, they saw much improvement in blowing off the water which kept the ink jet printing process from running or smearing. If you need flexibility in your blowing application, EXAIR offers a variety of kits with different types of nozzles to accommodate the best blowing feature for your application. If you would like to discuss these options, you can contact an EXAIR Application Engineer, and they will be happy to help.
Early one morning we received a call from a local metal stamping company that had a problem. They had outstripped the volumetric capacity of their (2) 50 HP air compressors.
They were using open copper tubes to facilitate separating the part from the die on the upstroke and then blow the part backwards into the collection chute. The (5) 1/4” copper tubes were all connected to a single manifold with a valve to control each tube. Compounding their compressed air shortage was that this setup was duplicated on approximately (8) presses. Per the plant they run the presses for approximately (4) hours per day. The volume of air required for one press was calculated as:
One 1/4” open copper pipe consumes 33 SCFM @ 80 PSIG, therefore:
Due to the award winning design of EXAIR’s engineered air nozzles the plant achieved faster separation of the part from the die and greater efficiency moving the part to the collection chute, while averting the need to purchase a larger air compressor. They are saving air, reducing energy costs and lowering the noise level in their facility.
If you would like to discuss saving air and/or reducing noise, I would enjoy hearing from you…give me a call.
The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle. Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level. Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.
The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.
The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel. All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.
Also available, for extra blowing force, are the HP1125 and HP1125SS. The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.
Shim sets for any of the 2″ Flat Super Air Nozzles are available. The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″. For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.
As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle. If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well. Check it out as well.
If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
Here on the EXAIR Blog we frequently discuss dead-end pressure as explained in OSHA Standard 1910.242(b). This directive states that the when compressed air is used for cleaning purposes, the dead-ended pressure must not exceed 30 psig. When pressures greater than this occur, there is potential for an air embolism. This animation shows and explains how an air embolism can affect the body.
EXAIR’s Flat Nozzles adhere to this OSHA directive. The Flat Nozzles consist of three primary components: the body, the cap, and the shim. The thickness of the shim will dictate the flow and force through the nozzle and can be easily adjusted. The cap slightly protrudes from the body and shim, creating a gap when it is pressed up onto the skin. By ensuring that there is always an avenue for that air to escape, there is no potential for it to be dead-ended.
EXAIR’s flat nozzles are available in two sizes: 1” and 2”. Each size has a shim set that can be purchased for adjusting both the flow and force from the nozzle. These nozzles are available in both zinc/aluminum alloy as well as 316 grade Stainless Steel. They can be used by themselves, installed on our Safety Air Guns, or in conjunction with our Stay Set Hoses that allow for easy re-positioning.
You may have seen (or used) the plastic flat nozzles that come in a variety of different colors. EXAIR’s flat nozzle is a safe, efficient, and more robust replacement that will maintain a similar airflow pattern at a dramatically reduced operating cost. Where plastic nozzles may become damaged or break off, the rigid construction of EXAIR’s Flat Nozzle will not. In addition to be safe, durable, and reliable, EXAIR’s flat nozzles also offer a reduced sound level compared to these styles of nozzle. Reducing sound is another directive that OSHA 29 CFR 1910.95 covers. If you’re using an unsafe nozzle in your facility, OSHA can quickly begin assessing fines for each violation. They don’t announce their visits beforehand, so make sure you do your due diligence and assess your compressed air blowoff products yourself!
If you would like to discuss how to make your compressed air use safer and more efficient, give us a call. Our team of highly-trained Application Engineers is standing by, ready to help you make the switch to an Intelligent Compressed Air Product.
Recently, I was working with a customer looking for a Premium Reversible Drum Vac and wanted it shipped to the Northwest Territories of Canada – which we could do! It got me to thinking, what are the farthest US state and territory locations EXAIR has shipped to in the North, South, West and East directions. I ‘scoured’ the records and came up with these.
Furthest North- We have shipped to Prudhoe Bay, Alaska. Most recently, believe it or not, we shipped a NEMA 4X Cabinet Cooler to an Oil and Natural Gas Exploration Company. Goes to show that even the coldest environments still have the need to provide cool, clean, dry air to cool and protect electronics in electrical enclosures.
Furthest South – We have shipped to the US Territory of Puerto Rico, city of Santa Isabel. An Aerospace company needed a strong, laminar blast of air and utilized a 6″ Stainless Steel Air Knife. An Air Knife offers a quiet, efficient way to clean, dry or cool parts, webs, or conveyors.
Furthest West- We have shipped to the US Territory of Guam. The local University ordered a model 1111-4 Super Air Nozzle Cluster, for a good strong blast of air flow for a cleaning operation. The model 1111-4 delivers 3.2 lbs of force, at just 82 dBA of sound. A safe and efficient nozzle for blowoff operations.
Furthest East- We have shipped to Eastport, Maine. The customer in Eastport ordered a Line Vac and a section of Conveyance Hose. The Line Vac is a great tool for conveying large volumes of material over long distances, through a standard hose or tube. The compact design features large throat diameters for maximum throughput capability.
It was interesting to look back and see all the places that EXAIR has shipped. We have customers from all over the globe. If you are outside the of 50 US States and Canada, we have a dedicated team of International Application Engineers that will work with you to select the best EXAIR product for your process and application, and direct you to your local International Distributor.
If you would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
In most “general” blowoff applications, the conical airflow pattern from a standard round shaped nozzle is ideal when trying to remove dust or light debris from the surface of a part or material. However in certain applications, a focused, laminar flow of air is required to produce the desired result, such as cleaning peanut butter from a fill nozzle or ejecting parts in a stamping operation.
EXAIR manufactures our 1″ Flat and 2″ Flat Super Air Nozzles, which provide a 1″ and 2″ (respectively) wide, forceful stream of high velocity, laminar airflow while consuming only a small amount of compressed air. Both the 1″ and the 2″ are available in Zinc Aluminum alloy, rated up to 250°F (121°C), or 316 Stainless Steel construction, rated up to 1,000°F (538°C)
Their unique design incorporates a specially designed, replaceable shim, to maintain a critical gap between the cap and body, resulting in the focused airflow. They are shipped from stock with a .015″ shim installed.
Using the optional shim kit, the shims can be changed out to .005”, .010” or .020”, which allow you to increase or decrease the force and flow by either opening or closing the gap, providing more or less force and flow to meet the demand of the application.
(Here’s a short video showing how easy it is to change out the shims)
We also offer our High Power versions of these nozzles which feature a thicker shim installed (0.025″) for applications requiring higher thrust and velocity.
If you have an application you would like to discuss or to see how the Flat Super Air Nozzles might improve your process, give me a call, I’d be happy to help.