Video Blog: EXAIR Efficiency Lab

The video below is a brief introduction to the EXAIR Efficiency Lab, a free service provided by EXAIR for customers within the USA and Canada.

If you have a single point blowoff that does not have an engineered nozzle, or if you have a wider format blowoff, manifold or home-made drilled pipe, contact an Application Engineer with EXAIR and let us help you to reduce your energy waste. Following are some examples of product where we have helped to save some serious air and reduced noise levels which heightens employee comfort.

Non-engineered blowoffs

Drilled and soldered copper pipe.

Custom manufactured inefficient pipe blowoff

 

The EXAIR Efficiency Lab

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Energy Rebates and EXAIR Products

In case it goes unnoticed, EXAIR focuses on engineered compressed air point of use products to ensure that our customers are utilizing their costly utility as efficiently as possible.  The main benefits to purchasing EXAIR products are the support you receive from us at EXAIR, the quality of the product, the savings in compressed air, and the increase in safety.  Another added benefit is a large number of utility companies are offering rebates on the purchase of engineered nozzles, just like the Super Air Nozzles that EXAIR offers.

Many energy providers offer these energy rebates for commercial or industrial users.  Here in the Cincinnati area, Duke Energy offers rebates on items such as lighting, air compressors, engineered air nozzles, heaters / dryers for extrusion machines, energy management systems, variable frequency drives, data center equipment, even food service equipment, custom incentives, and many other items.

Duke Energy Rebate

Example of our local energy rebate offering for Engineered Nozzles

For each engineered compressed air nozzle that is installed, in order to meet the rebate requirements they must flow less than or equal to given flow rates in SCFM at 80 psig inlet pressure. The pipe sizes, flow rates, and EXAIR equivalents are shown below.

EXAIR Engineered Air Nozzle Part Number EXAIR Flow Rate @ 80 psig
#1102/#1103 – 1/8 NPT 10 SCFM
#1100/#1101 – 1/4 NPT 14 SCFM
#1108SS-NPT/#1109SS-NPT/#1110SS-NPT
All are 1/8 NPT
2.5, 4.9, 8.3 SCFM
respectively
#1003 – 3/8 NPT 18 SCFM

By just replacing the nozzles the customer saved 2.7 SCFM per nozzle.If we take an example such as the EXAIR Case Study  shown below for 1/4″ copper tube that was being used as an open ended blow off.  The copper tubes were consuming 19.6 SCFM at 100 psig inlet pressure, there were 10 machines with one line per machine operating 40 hours, 52 weeks per year.   The customer retrofitted the open pipes with a model 1100 Super air nozzle and was able to reduce the air consumption by 2.7 SCFM per nozzle.  If they were to purchase these nozzles this year, current list price for a model 1100 Super Air Nozzle is $36.00 USD, then apply for the energy rebate offered by Duke Energy and receive $20.00 per nozzle replaced.  The total savings and return on investment is shown below.

Case Study 1561

EXAIR Model 1100 Super Air Nozzle Replaces Open Copper Pipe Blow Off

10 nozzles x 2.7 SCFM = 27 SCFM  x 60 minutes per hour x 8 hours per day x 5 days per week x 52 weeks per year = 3,369,600 SCF of compressed air saved per year.

3,369,600 / 1,000 SCF x $.25 = $842.40 USD savings in compressed air per year.

Cost Savings per week = $16.20 USD

Total purchase cost is  $36.00 x 10 nozzles = $360.00 USD

Energy Rebate = @20.00 per nozzle x 10 nozzles  = $200.00 USD in rebates.

$360.00 USD purchase price – $200.00 USD energy rebate = $160.00 USD final purchase cost.

Return on investment at a savings of  $16.20 USD per week is

$160.00 / $16.20 = Less than 10 weeks pay back!

By applying for the energy rebate this customer could reduce the ROI of this air savings project from just over 22 weeks (which is still very good) to less than 10 weeks.

If you would like to learn more about whether there are Industrial energy rebates available in your area, contact an Application Engineer and let us know where you are located and who your energy provider is.

We will help you determine the correct engineered solution to save your compressed air as well as help you to apply for eligible energy rebates in your area.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Calculating Compressed Air Cost & Savings Made Easy

If you have ever looked through our catalog, website, blog, twitter feeds, or even our Facebook page, you will see that we can almost always put a dollar amount behind the amount of compressed air you saved by installing EXAIR’s Intelligent Compressed Air Products.   No matter which platform we use to deliver the message, we use the same value for the cost of compressed air which is $.25 per 1,000 Standard Cubic Feet of compressed air. This value is derived from average commercial and industrial energy costs nationwide, if you are on either coast this value may increase slightly. On the positive side, if your cost for compressed air is a bit more, installing an EXAIR product will increase your savings.

So where does this number come from?   I can tell you this much, we didn’t let the marketing department or anyone in Accounting make it up.   This is a number that the Engineering department has deemed feasible and is accurate.

To calculate the amount we first look to what the cost per kilowatt hour is you pay for energy.  Then we will need to know what the compressor shaft horsepower  of the compressor is, plus the run time percentage, the percentage at full-load, and the motor efficiency.

If you don’t have all of these values, no worries.   We can get fairly close by using the industry accepted standard mentioned above, or use some other general standards if all you know is the cost of your electricity.

The way to calculate the cost of compressed air is not an intense mathematical equation like you might think.  The best part is, you don’t even have to worry about doing any of the math shown below because you can contact us and we can work through it for you.

If you prefer to have us compare your current compressed air blow off or application method to one of our engineered products, we can do that AND provide you a report which includes side by side performance comparisons (volume of flow, noise, force) and dollar savings. This refers to our free Efficiency Lab service.

EXAIR's Efficiency Lab is a free service to all US customers.

EXAIR’s Efficiency Lab is a free service to all US customers.

If you already know how much air you are using, you can use the Air Savings Calculators (USD or Euro) within our website’s knowledge base. Just plug in the numbers (EXAIR product data is found on our website or just contact us) and receive air savings per minute, hour, day and year. We also present a simple ROI payback time in days.

Now, back to the math behind our calculation.
Cost ($) =
(bhp) x (0.746) x (#of operating hours) x ($/kWh) x (% time) x ( % full load bhp)
——————————————————————————————————————————
Motor Efficiency

Where:
bhp
— Compressor shaft horsepower (generally higher than motor nameplate Hp)
0.746 – conversion between hp and KW
Percent Time — percentage of time running at this operating level
Percent full-load bhp — bhp as percentage of full load bhp at this operating level
Motor Efficiency — motor efficiency at this operating level

For an average facility here in the Midwest $0.25/1,000 SCF of compressed air is accurate.   If you would like to attempt the calculation and or share with us your findings, please reach out to us.   If you need help, we are happy to assist.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Compressed Air Can Be Costly – EXAIR Can Help You Save It

Growing up across the street from an old fashioned service station does have its perks.   This was one of the old 76  gas stations that still had a garage where a mechanic would fix your car, as well as you could get gas if you needed to.   They even had the rubber hose that would ring a bell when you drive over it.  One of the other things this station had was a compressed air hose that ran to the outside of the building and offered free compressed air to any passer by so they could fill up their tires as needed.   Normally it just had a very simple tire chuck on the end that would connect to the Schrader valve on your car tire.  This station is still there, they no longer sell gas, and they have also removed the bell ringing air hose that runs outside.  If you need a tire filled now, you have to either catch them during normal business hours or move on to the next gas station and hope they have some form of compressed air available.

The full service gas stations for the most part have been replaced by gas stations with convenience stores attached.   They carry more junk food than they do products for your car and they have no need to own or operate an air compressor.   Their customers still have that need though so there are now small stand alone compressed air stations.   These range from small shoebox sized units that you pay a few quarters for, up to the unit I noticed today while filling up my car.

Standalone air compressed for tire inflation.

Standalone air compressed for tire inflation.

This unit takes credit cards, regulates the compressed air to the user selected pressure, and all you have to do is hook it to your cars valve stem.  This is far from free, and the reason is, compressed air is a costly utility.  If you don’t believe us when we repeatedly talk about how much money you can save on compressed air by installing our engineered compressed air nozzles, Super Air Amplifiers or Super Air Knives (among others), then accept a challenge from me.  Contact an EXAIR Application Engineer to discuss any point of use compressed air applications that you have in your facility.   While you are waiting to get the in stock, shipped same day, Intelligent Compressed Air Products® received, monitor your compressed air use and the energy use on your compressor.  Install the EXAIR products once you receive them and continue to monitor your air and energy consumption.   If you don’t see a decrease within these two areas, call me and return the items.   We honor a 30 day guarantee on stock products just so you can make sure you are saving air, and getting the best performance out of your compressed air system.

Brian Farno
BrianFarno@EXAIR.com
@EXAIR_BF

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