EXAIR Nano Super Air Nozzles for Science and Industry!

A few weeks ago I was on vacation with my family. My wife and I had taken our three daughters to Columbus, OH for three days after camping in a tent for a few days. One of the focal points to the trip was COSI, the Center of Science and Industry. In case you live anywhere near Columbus, OH and have not heard of how amazing this interactive museum is, you should definitely check it out. This isn’t your normal museum.

While the Mythic Creatures exhibit and the Jim Henson exhibit were both absolutely amazing for my 9, 6 and 4 year old daughters, it was also entertaining for my wife and myself. Now you may be asking what does this interactive science place and trip with kids have to do with EXAIR.

Well, while my daughters and I were watching this enormous pendulum that knocks ball bearings off boxes every few minutes I could hear that all too familiar, gentle sound of compressed air blowing every now and then. I couldn’t however see where the noise was coming from.

COSI Pendulum

As we wandered through the different sections I saw several examples of compressed air use but none were the exact sound or display I had heard. When we were walking through the Space exhibit just above where the pendulum was located and that gentle sound was getting closer. All of a sudden I saw it. Next thing I know I look up and my 6 year old was using a joystick to control a scaled down Lunar Lander propelling it in circles. This was where the sound was coming from.

Propelled Lunar Lander

While I was amazed by this interactive piece I could tell they were using compressed air and I was curious as to how it was working. That’s when I noticed the distinct design of our Nano Super Air Nozzle on the bottom of the Lander. Here’s a close up picture, well as close as the handrail would allow me to get without over reaching.

EXAIR Model 1110SS-NPT – Nano Super Air Nozzles

The interesting part to this is how this setup gives an idea of the amount of thrust given off by a nozzle that only consumes 8.3 SCFM of compressed air when powered at 80 psig inlet pressure. These nozzles can easily be fitted to blast debris or moisture out of small pockets or hard to reach areas. They also can be used to help direct product that may be getting diverted to a new conveyor. And, obviously, they can be used to propel scale models of lunar landers. 

If you would like to discuss any application for point of use compressed air, and I do mean ANY, give us a call. If I can’t help with the application we will at the very least do our best to send you in the right direction.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR Air Nozzles – Here’s Their Simple ROI

Return on Investment, or ROI, is the ratio of profit over total investment.  Many people use it to check stocks, financial markets, capital equipment, etc.  It is a quantitative way in determining the validity for an investment or project.   You can use the ROI value to give a measurable rate in looking at your investment.

For a positive ROI value, the project will pay for itself in less than one year.  Any negative values would represent a high-risk investment.  In this blog, I will compare the ROI when replacing a ¼” NPT open pipe with a model 1122 2” Flat Super Air Nozzle.  Let’s start by looking at Equation 1 to calculate the Return on Investment:

Equation 1:  ROI = (Total annual savings – Total Project Cost) / Total Project Cost * 100

The second part of the equation, Total Project Cost, is the cost of the nozzles plus the labor to install them onto the machine.  The model 1122, 2” Flat Super Air Nozzle, has a price of $70.00 each.  The cost of a ¼” NPT Pipe that is roughly 2” long is around $1.50 each.  What a difference!  How could EXAIR been in business for over 35 years?  Let’s continue on with the Return on Investment…

The amount of time required to install the nozzles to the end of a pipe is 1/2 hour (generously).  The labor rate that I will use in this example is $75.00 per hour (you can change this to your current labor rate).  The labor cost to install a nozzle is $35.00.   The Total Project Cost can be calculated as follows: ($70 – $1.50) + $35.00 = $103.50.  The next part of the equation, Total annual savings, has more complexity in the calculation, as shown below.

As a reference, EXAIR Super Air Nozzles for compressed air would be considered like LED light bulbs for electricity.  The open pipes and tubes would represent the incandescent light bulbs.  The reason for this parity is because of the amount of energy that the EXAIR Super Air Nozzles can save.  While LED light bulbs are a bit more expensive than the incandescent light bulbs, the Return on Investment has a high percentage, or in other words, a short payback period.  On the other hand, the open pipe is less expensive to purchase, but the overall cost to use in your compressed air system is much much higher.  I will explain why.

To calculate the Total Annual Savings, we need to generate a blow-off scenario (You can use your actual values to calculate the ROI for your project).  In this example, I will compare the ¼” NPT open pipe to the 2” Flat Super Air Nozzle.  (The reason behind this comparison is that the model 1122 can screw directly onto the end of the 1/4” NPT pipe.)   The amount of compressed air used by a 1/4” NPT open pipe is around 140 SCFM (3,962 SLPM) at 80 PSIG (5.5 Bar).  The model 1122 has an air consumption of 21.8 SCFM (622 SLPM) at 80 PSIG (5.5 Bar).  At an electrical rate of $0.08 per Kilowatt-hour, we see that the cost to make compressed air is $0.25 per 1000 standard cubic feet, or $0.25/1000SCF.  (Based on 4 SCFM per horsepower of air compressor).

To calculate an annual savings, let’s use a blow-off operation of 8 hours/day for 250 days a year.   Replacing the ¼” NPT open pipe with a model 1122, it will save you (140 SCFM – 21.8 SCFM) = 118.2 SCFM of compressed air.  To put this into a monetary value, the annual savings will be 118.2 SCFM *$0.25/1000SCF * 60 Min/hr * 8hr/day * 250 day/yr = $3,546/year.  Now if you have more than one blow-off spot in your facility like this, imagine the total amount of money that you would save.

With the Total Annual Cost and the Project Cost known, we can insert these values into Equation 1 to calculate the ROI:

ROI = (Total annual savings – Total Project Cost) / Project Cost * 100

ROI = ($3,546 – $103.50) / $103.50 * 100

ROI = 3326%

With a percentage value that high, we are looking at a payback period of only 9 days.  You may look at the initial cost and be discouraged.  But in a little over a week, the model 1122 will have paid for itself.  And after using it for just 1 year, it will save your company $3,546.00.  Like with any great idea, the LED light bulb clicked on in my mind.  What could be the total savings if you looked at all the blow-off applications in your facility?

EXAIR Nozzles

In my experience, a loud blowing noise from your equipment is generally coming from an open pipe or tube.  With these “cheap” ways to blow compressed air, it will cost your company a lot of money to use as shown in the example above.  If you would like to team up with EXAIR to set up ways to increase savings, improve productivity, and increase safety, you can contact an Application Engineer to get started.  It can be as simple as screwing on a Super Air Nozzle.

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

OSHA Safety, Efficiency, and Flexibility from Engineered Compressed Air Nozzles

Throughout my years here at EXAIR as well as my years in the metal cutting industry, one of the most common quick fixes I see in production environments for compressed air blowoffs in a process is an open copper pipe that is contorted into a position, pinched at the end, and more often than not kinked from repositioning. I call this a quick fix because it does blow air, more often than not it will get production up and running, but it does not meet or exceed OSHA standards for safety and is an inefficient use of compressed air. [OSHA Standards 29 CFR 1910.242(b) and 29 CFR 1910.95(a)]

EXAIR Super Air Nozzles that are easy replacements for 1/8″ and 1/4″ Copper pipe.

The first engineered solution I could offer to prevent any costly OSHA fines and to lower the ambient noise level caused by these blowoffs is to implement an EXAIR Engineered Air Nozzle. We offer a wide variety of nozzles ranging from a 4mm thread up to a 1-1/4″ NPT thread. With this wide range comes a wide variety of forces and flows as well.

Today, I would like to focus on the common sizes of copper blowoffs which are 1/8″ and 1/4″. To simply adapt a nozzle to copper line a compression fitting can be easily sourced, often from EXAIR, and convert the copper tubing in place to an NPT threaded outlet for easy installation of an EXAIR nozzle. More often than not a compression fitting is how the copper tubing is tied into the machine’s compressed air system.

We have a total of 37 engineered air nozzles from stock that will easily fit a compression fitting which goes to a 1/8″ NPT or 1/4″ NPT thread. Several of these are also adjustable through a gap adjustment or a patented shim adjustment to vary the force and flow out of the nozzle from a forceful blast to a gentle breeze in order to me your application needs. What if you want to eliminate the copper line and compressions fittings?

EXAIR offers a replacement option for the ever-common copper tube that is more robust and does not require a tool to be properly repositioned. We currently offer twenty-four different models of our Stay Set Hoses that can be easily connected to any of the nozzles mentioned above. The lengths that are available are 6″ (152mm), 12″ (305mm), 18″ (457mm), 24″ (610mm), 30″ (762mm) and 36″ (914mm).

These lengths are available with two separate connection options. 1/4″ MNPT x 1/4″ MNPT or 1/4″ MNPT x 1/8″ FNPT. The Stay Set Hoses can easily be bent by hand into position for a precise placement of the air pattern from the engineered nozzle attached to it. This permits operators a tool free adjustment for fast and reliable location to keep production up and running. They can also be paired with Magnetic Bases.

EXAIR Magnetic Bases are available in single outlet or dual outlet configurations. Both include a 100 lb. pull magnet that will hold tight to any ferrous metal surface for secure mounting, as well as a quick 1/4 turn miniature valve on each outlet. This permits independent customization of the force our of each output for the dual outlet mag base. Each magnetic base offers a 1/4″ FNPT inlet port and outlet port. We offer these with any of combination of the Stay Set Hoses mentioned above as well as any of the Super Air Nozzles mentioned above.

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

The Super Air Nozzles, Stay Set Hoses, and Magnetic Bases can be easily combined before they ship to your facility to make a complete blowoff station that is easily installed and adjusted to fit any of the needs your process may have for a point of use blowoff. If you want help determining how much compressed air you would save by replacing the open pipe blowoffs with an engineered solution like a Stay Set Magnetic Base Blowoff System please contact myself or any Application Engineer here at EXAIR.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Flat Super Air Nozzles

 

EXAIR’s Flat Super Air Nozzles provide a 1” or 2” wide airstream with hard-hitting force. All of EXAIR’s Flat Super Nozzles adhere to OSHA Standard 29 CFR 1910.242(b) for dead-end pressure, providing a safe and efficient method of delivering a strong blast of air.

The flow and force from the Flat Super Air Nozzle is adjustable by regulating the pressure supplied to it as well as by installing different thicknesses of shims. Thicker shims provide more force and flow, while a thinner shim will reduce the force and flow as well as the overall air consumption. This makes the Flat Super Air Nozzle and ideal solution for applications that may require variable force for different applications.

The nozzles are also available in your very own Blowoff System that can be customized to fit the exact application. You have the ability to put together the best combination of nozzle, Stay Set Hose, and Magnetic Base to suit your needs. Available with either a single or dual Magnetic Base and any of our Stay Set Hoses, there’s many different possibilities. To begin:

  1. Select the Air Nozzle you’ll need.

EXAMPLE: HP1125SS 2” High Power Stainless Steel Super Air Nozzle

  1. Then select the length of Stay Set Hose. They’re available in lengths ranging from 6”-36”.

EXAMPLE: An HP1125SS with a 24” Stay Set Hose would be an HP1125SS-9224.

  1. Finally, you have the option to also select a Magnetic Base if necessary. These are available with either a one outlet Magnetic Base, or Two Outlet which would include (2) separate nozzles. For a single outlet, change the second digit of the “added on” dash number to a “3”. For a two outlet, change that number to a “4”.

 EXAMPLE: An HP1125SS with 24” Stay Set Hose and Dual Magnetic Base is a Model HP1125SS-9424.

bok_1122-9412_400

This allows you to customize the solution using ANY nozzle and ANY length Stay Set Hose, creating a custom solution for your application. If you’d like to talk about any of our Super Air Nozzles and which would be best for your application, feel free to give us a call.

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

 

Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

capture.jpg
Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

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

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

 

 

The Case For EXAIR Swivel Fittings

One of the more common questions we get here in the Application Engineering department at EXAIR is…

“What’s the best angle to position a Super Air Nozzle?”

The simple (and perhaps a little snarky, but I swear that’s not intended) answer is…

“The angle it takes to get the results you need.”

But wait, there’s more…we’re not going to leave anybody hanging like that. Many blow off applications are going to be best served by a “sweep” of air, at a low angle. That will be ideal for removing a light layer of dust from a relatively flat and smooth surface. A bit larger angle, relative to the surface, may be necessary if you need some impingement force to dislodge sticky, clumpy, or mildly adhesive debris.  Rarely will you want to blow directly, at a perpendicular angle, to a material’s surface.  An exception to this might be if you’re trying to remove excess moisture from a porous and thin material, like a web fiber.

Regardless of what angle you need to aim your Super Air Nozzle, there are several ways to do it.  You can use a compression fitting them onto bendable copper tubing…just don’t bend it too much or too often.  We’ve got Stay Set Hoses that allow for quick & easy repositioning…they come in lengths from 6″ to 36″, and are in stock.

EXAIR Stay Set Hoses and Swivel Fittings are ideal for installation and positioning of your Super Air Nozzle.

If you want to hold it in place firmly and securely, you’re looking for a Swivel Fitting.  They’re available for almost all of our Super Air Nozzles, from the Atto to the 1″ NPT Model 1114 High Force Super Air Nozzle.  They offer 50° of total movement, and are made of Stainless Steel for durability in most any environment.

EXAIR Swivel Fittings have male NPT threads on one end, and female NPT on the other.  The smaller Swivels, for the Atto, Pico, and Nano Super Air Nozzles, have M4x0.5mm, M5x0.5mm, and M6x0.75mm female threads, respectively, in the ball of the swivel itself for direct threading of these small Super Air Nozzles.

EXAIR’s Swivel Fitting Family

Swivel Fittings can also be used with a host of other EXAIR products.  In addition to the Super Air Nozzles, for example, they’ve historically been very popular with our Air Amplifiers.  Here’s a short informational video showing just how versatile they are:

EXAIR Intelligent Compressed Air Products are made to be easy to install & operate.  This is our intent from Research & Development, to Shipping & Receiving.  If you have questions, give me a call.  I want you to get the most out of our products!

Russ Bowman
Application Engineer
EXAIR Corporation
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