Air Entrainment & EXAIR’s Intelligent Compressed Air Products

Air entrainment is a term that we bring up quite often here at EXAIR. It’s this concept that allows many of our products to dramatically reduce compressed air consumption. The energy costs associated with producing compressed air make it an expensive utility for manufacturers. Utilizing engineered compressed air products that will entrain ambient air from the environment allow you to reduce the compressed air consumption without sacrificing force or flow.

Entrainment
EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Products such as the Super Air Knife, Super Air Nozzle, Air Amplifier, and Super Air Wipe all take advantage of “free” air that is entrained into the primary supplied airstream. This air entrainment occurs due to what is known as the Coanda effect. Named after renowned Romanian physicist, Henri Coanda, the Coanda effect is used in the design of airplane wings to produce lift. As air comes across the convex surface on the top, it slows down creating a higher pressure on the underside of the wing. This creates lift and is what allows an airplane to fly.

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EXAIR Super Air Nozzle entrainment

This is also the same principle which is allowing us to entrain ambient air. As the compressed air is ejected through a small orifice, a low-pressure area is created that draws in additional air. Our products are engineered to maximize this entrained air, creating greater force and flow without additional compressed air. Super Air Amplifiers and Super Air Nozzles are capable of up to a 25:1 air entrainment ratio, with just 1 part being the supplied air and up to 25 times entrained air for free!! The greatest air entrainment is achieved with the Super Air Knife at an incredible ratio of 40:1!

This air entrainment principle allows you to utilize any of these products efficiently for a wide variety of cooling, drying, cleaning, or general blowoff applications. In addition to reducing your compressed air consumption, replacing inefficient devices with engineered products will also dramatically lower your sound level in the plant. Sound level in some applications can even be reduced down to a point that would eliminate the need for hearing protection with the OSHA maximum allowable exposure limits set at 90 dBA for an 8-hour shift.

If you have inefficient blowoff devices in your facility, give us a call. An Application Engineer will be happy to help you select a product that will “quietly” reduce your compressed air consumption!

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

Custom Products from EXAIR Meet Your Specifications

Since EXAIR manufactures and distributes our own products, we have the flexibility to provide custom products, special processing, unique packaging and more. If your process or specifications are something special, let us know and we will do our best to accommodate any special considerations you might need. Following is one example for a customer who purchases air guns.

Several months ago I received a call from a company that was looking for a specialized air gun.  This company was involved in the servicing of highly specialized measuring equipment and needed a safe, quiet, & efficient air gun that also had to be completely oil/contamination free.   This was to ensure no contamination would result from using the air gun on any of their equipment.  Ultimately this meant that every air gun component needed to be washed,  rinsed and dried to ensure there was no residual oils or dirt from manufacturing left on or in any component of the gun.

Our customer decided on the highly versatile Vari-Blast Compact Safety Air Gun with the award-winning Nano Super Air Nozzle, specifically models 1698SS and the 1698SS-6.  EXAIR presented a written process to the customer. This process explained how we would identify and manufacture their specific air gun in order to assure the customer that would receive a consistently clean air gun, every time.

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EXAIR’s Award Winning Nano Super Air Nozzle Performance Characteristics
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1110SS Specifications
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1698SS
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1698SS-6

Additionally the customer had specifications requiring special packaging as they were going to ship these globally to their service team members.  To ensure safe arrival no matter where they are shipped,  EXAIR provides special handling and packaging which exceeds their requirements.

Also, when you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call.  We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Benefits of Atomized Liquid Nozzles vs. Liquid Nozzles

There are a great many applications that require a spray (as opposed to a stream) of liquid. Certain droplet sizes, and flow rates, are beneficial for certain applications. For example, if you’re fighting a fire, you want as high of a flow rate as possible – the more water you douse the fire with, the quicker it goes out.  You also want a fairly large droplet size, since a mist would tend to evaporate instead of extinguishing the flames.

Pressure washers also benefit from higher (though not near as high as fire hose) flow rates, and droplet sizes.  You want an appreciable flow rate, because that means high velocity, and good sized droplets combine that velocity with their relative mass to “blast” away dirt and detritus from the surface.

Medicine delivery devices, like asthma inhalers, are designed to produce mid-sized droplets, but pretty low (and controlled) flows.  The droplets need to be small enough to efficiently spread the medicine through the breathing passages, but large enough to where they won’t evaporate before they ‘plant’ on the nasal & bronchial membranes to get absorbed.

These are examples of “liquid-only” nozzles…no other media or means of force are used to effect the spraying action.  Most of the time, the droplet sizes in these applications are measured in hundreds of microns, which “liquid-only” nozzles are ideally suited to generate.  Other applications, however, call for much smaller droplet sizes…such as those only attainable through atomization.

EXAIR Atomizing Spray Nozzles use compressed air to create a fine mist of liquid, with droplet sizes as low as 22 microns.

A typical “liquid-only” nozzle is capable of producing droplet sizes of 300-4,000 microns. Atomizing Nozzles’ droplet sizes are consistently under 100 microns, and can be as small as 20 microns!

Small droplet size is key to cost effectiveness in many applications:

  • Think about expensive coatings…the smaller the droplet size, the better and more even the coverage, and the less you have to spray (and pay) out.
  • Or humidification…smaller droplet size means more stays airborne, for longer, and in a larger space.
  • Petroleum based lubricants, by their nature, only require a thin layer for best results.  Smaller droplets make as even and thin of a layer as possible.
  • Dust control is much more effective with smaller droplet sizes, since the longer the mist lingers in the air, the more dust particles the individual droplets will adhere to…and then drop with them to the surface.  This also prevents getting the surface of the material any wetter than it has to be.
142 distinct models. 8 different patterns. Liquid flow rates from 0.1 to 303 gallons per hour. If you’ve got a spraying application, EXAIR has an Atomizing Nozzle for you!

If you’d like to discuss a liquid spraying application, I’d love to hear from you.  Call me.

Russ Bowman
Application Engineer
EXAIR Corporation
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Adjustable Air Amplifiers Aren’t Just About Adjustability

Adjustability is a key feature for a great many devices:

  • An adjustable wrench – or as I like to call it, the trusty “all 16ths” – is my go-to for work around the house involving anything with a hex…fittings under the sink when I’m cleaning out a drain, nuts & bolts on furniture or household items needing some tightening (or loosening,) etc.  I don’t get out my combination-end wrenches for much except automobile maintenance.
  • Speaking of sinks, my kitchen faucet lets me adjust water flow (and temperature) which is important because I use different flow rates (and temperatures) if I’m getting a tablespoon of water, or if I’m rinsing my hands, or if I’m filling the sink to do dishes.
  • Speaking of tablespoons, I’ve even got an adjustable measuring spoon that lets me get a full tablespoon, a half a teaspoon, or anywhere in between, by moving a lever block back & forth in the spoon head.

Adjustability is a key feature for several EXAIR Intelligent Compressed Air Products too…like our Adjustable Air Amplifiers.  The ‘adjustable’ part has to do with setting the air flow:

Just loosen the locking ring, and you can thread the plug out of, or in to, the body to increase, or decrease the flow and force of the developed flow.  There’s a hole in the plug (opposite the “EXAIR.com” stamp) so you can use a spanner wrench (another adjustable tool!) to thread the plug in or out.

You can get an amazing range of flow from a little twist*:

These are the performance values for a Model 6042 2″ Aluminum Adjustable Air Amplifier with a compressed air supply pressure of 80psig. Regulating the pressure can give you even lower…or higher…flows.                                              *0.002″ to 0.010″ is about 1/4 turn of the plug.

A gap of about 0.010″ is about the max for 80psig supply pressure.  Above that, the air flow overwhelms the Coanda profile, creating a turbulent ‘storm’ in the throat, hampering the efficiency and effectiveness.  The proper “adjustment” for that is to select the next larger Air Amplifier!

While the range of air flow is certainly impressive, their versatility is another major factor in their selection.  I reviewed our Application Database (registration required) for real-life details on Adjustable Air Amplifiers “in the field” and found a litany of other benefits that made them better suited to particular installations than a Super Air Amplifier:

  • A customer who builds automated equipment incorporates the Model 6031 1-1/4″ SS Adjustable Air Amplifier to blow open bags with a puff of air as they move into position on an automated filling machine. They use it because it’s available in stainless steel construction, and it’s still compact & lightweight.
  • A mattress manufacturer uses Model 6043 3″ Aluminum Adjustable Air Amplifiers to  cool mattress springs.  They’re lightweight, the perfect size to match the springs’ profile, and they can “dial them out” for high heat removal before putting springs on a rubber conveyor.
  • A tier 1 automotive supplier has Model 6234 4″ SS Adjustable Air Amplifier Kits installed on their robotic paint line to blow off moisture from parts to prevent water spotting between the wash cycle and the oven.  They use them because the stainless steel construction holds up to high heat due to the proximity to the ovens.
  • A food plant uses Model 6031 1-1/4″ SS Adjustable Air Amplifiers to improve the drying time of 3,000 liter mixers that must be washed between batches of different products.  The stainless steel construction holds up to the rigors of the frequent washdown in this area.
  • A bedding manufacturer replaced a regenerative blower with a Model 6041 1-1/4″ Aluminum Adjustable Air Amplifier for trim removal on stitched fabric at bedding manufacturer.  The blower was prone to failure from lint & dust; the Air Amplifier, with no moving parts, is not.  It’s also compact, lightweight, and virtually maintenance free.
  • A light bulb manufacturer installed Model 6030 3/4″ SS Adjustable Air Amplifiers on the ends of open pipes that were used to cool mercury lamp wicks.  This reduced noise levels significantly while providing the same cooling rate, and the stainless steel construction holds up to the heat of the operation.

Because of the simplicity of their design, Adjustable Air Amplifiers are also extremely adaptable to custom applications.  We’ve added threads or flanges to the inlets and outlets of several different sizes, to accommodate ease of mounting & installation:

Among other custom Air Amplifiers, we’ve put (left to right) threads on the outlet, ANSI flanges on the inlet/outlet, Sanitary flanges on the inlet/outlet, and Sanitary on the inlet/ANSI on the outlet. How are you installing your Air Amplifier?

Adjustable Air Amplifiers are available in both aluminum and 303SS construction, to meet most any environmental requirements…except extreme high heat.  In those cases, the Model 121021 High Temperature Air Amplifier is rated to 700°F (374°C) – significantly higher than the Aluminum – 275°F (135°C) or the Stainless Steel – 400°F (204°C).  They’re commonly used to circulate hot air inside furnaces, ovens, refractories, etc.

A Model 121021 1-1/4″ High Temp Air Amplifier directs hot air to a rotational mold cavity for uniform wall thickness of the plastic part.

Adjustability.  Versatility.  Durability.  If you’d like to know more about the Adjustable Air Amplifier, or any of EXAIR’s Intelligent Compressed Air Products, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Calculating Static Friction To Eject Parts with Air

2″ Flat Super Air Nozzle

In today’s fast-paced world, companies are always looking for ways to do things faster, cheaper, more efficiently without sacrificing safety.

A cereal company had a high-speed system to check the quality of each box of cereal.  When a box did not meet the quality criteria for visual and/or weight, the box would be rejected.  The rejection system that they used was a quick blast of compressed air to remove the box from the conveyor line into a non-conforming bin.  For their first attempt, they tried to use a ¼” copper tube with a solenoid valve attached to a reservoir tank.  When a “bad” box was detected, the solenoid would be triggered, and compressed air would “shoot” the box off the rubber conveyor belt.  The ¼” copper tube can be an inexpensive, common, and easy-to-use device; but they found that the copper tube was very loud (above OSHA limits for noise exposure) and not very effective.  As a note, this company had a safety committee, and they wanted to keep all blowing devices below 80 dBA in this department.  The ¼” copper tube was around 100 dBA.  So, they contacted EXAIR to get our expertise on this type of application.

The cereal company gave me some additional details of the operation.  The box weighed 26 oz. (740 grams) with a dimension of 7.5″  wide by  11″ tall by  2 3/4″ deep (19 cm X 28 cm X 7 cm respectively).  The issue with the ¼” copper tube was the small target area compared to the area of the box.  With any slight variation in the timing sequence, the force would miss the center of mass of the box.  The box could then spin and remain on the conveyor belt.  This would cause stoppage and disruption in the system.  They asked if EXAIR had a better way to remove the defective boxes.

I recommended a model 1122, 2” Flat Super Air Nozzle.  The reason for this style of nozzle was for a variety of reasons.  First, we needed a larger area to “hit” the box.  This Flat Super Air Nozzle has a width of 2” versus the ¼” copper tube.  This increased the target area by 8 times.  So, any small variations in time, we could still hit the center of mass and remove the box.  The second reason was the force rating.  The model 1122 has a force of 22 oz. (624 grams) at 80 PSIG (5.5 bar).  This is slightly under the 26 oz. (740 grams) weight of the cereal box, but we are just sliding the box and not lifting it.  If we can overcome the static friction, then the box can be easily removed.  With Equation 1, we can calculate the required force.

Equation 1:

Fs = ms * W

Fs – Static Force (grams)

m– Static Friction

W – Weight (grams)

From the “Engineering Toolbox”, the static friction between rubber and cardboard is between 0.5 to 0.8.  If I take the worse case condition, I can calculate the static force between the belt and cereal box using Equation 1:

Fs = 0.8 * 740 grams

Fs = 592 grams

The model 1122 has a force of 22 oz. (624 grams), so plenty enough force to move the box from the rubber conveyor belt.

The third reason for this nozzle is the noise level.  The noise level of the model 1122 is 77 dBA, well below the safety requirement for this company.  Noise levels are very important in industries to protect operators from hearing loss, and the model 1122 was able to easily meet that requirement.  I added an additional reason for recommending the 2” Flat Super Air Nozzle; compressed air savings.  Companies sometimes overlook the cost when using compressed air for blow-off devices.  In this comparison, the ¼” copper tube will use 33 SCFM (934 SLPM) at 80 PSIG (5.5 bar) while the model 1122 will only use 21.8 SCFM (622 SLPM).  This is a 33% reduction in compressed air; saving them money.

At the intro, I mentioned that companies are looking to do things faster, cheaper, more effective without sacrificing safety.  For this company, we were able to increase production rates by removing every cereal box from the conveyor belt.  We also saved them money by reducing the compressed air requirement as well as keeping it safe by reducing noise.

If you have an application that needs products to be moved by air, you can contact an Application Engineer at EXAIR to help you with a solution.

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

General Good Ideas For The Compressor Room

When considering your compressor room all too often the phrase applies “out of sight and out of mind”.  Of course, we all know that is not a good approach to the compressor room or really anything in life.  Unfortunately, many of us take for granted that very system that delivers the power to keep our machines, equipment and tools operating.

Air Compressor
Compressor Room Located Outdoors

So, what can we do keep the ‘lungs” of our plants performing reliably and efficiently?  Since this Blog is about “General Good Ideas For The Compressor Room”, I have some points below for your consideration.

  • Ideally the compressor room should be centrally located to minimize the length of the pipes and allows for easier noise control. With long piping runs leaks become more likely and frictional losses are increased.
  • The compressor room should be sized to allow for easy maintenance and future expansion.
  • For efficient operation air compressors need clean intake air. Intake air that is dusty, dirty or contains gaseous contamination will reduce the efficiency and possibly the longevity of your equipment.
  • The compressor room needs adequate ventilation since air compressors generate significant heat. If excessive heat is allowed to build up it reduces the efficiency of the air compressor raising utility costs, causes compressor lubricant to break down prematurely that could possibly result in increased maintenance and compressor failure.
  • What is the velocity of the air through the main headers? If the speed is above 1200 FPM many dryers have reduced efficiency and speeds greater than this can also carry moisture past the drainage drop legs.
  • Excess friction caused by too small of a diameter piping creates pressure loss, which reduces efficiency and if the compressor is ran above its pressure rating to overcome the frictional losses increases energy consumption, maintenance costs and down time.

Now that your compressor room is shipshape in Bristol fashion, you might think that all is well.  While that may be true, chances are there are other significant additional savings to be had.  EXAIR specializes in point of use compressed air products that are highly efficient and quiet!  If you have any blow-offs that are open tube or howl as loud as the ghost of Christmas yet to come, check out EXAIR’s Super Air Nozzles.  They are highly efficient and quiet, in fact they meet OSHA Standard 29 CFR – 1941.95 for maximum allowable noise and OSHA Standard 29 CFR 1910.242 (b) for higher than 30 PSIG blow-off pressure.  All of EXAIR’s compressed air products are engineered to minimize compressed air consumption and take advantage of the Coanda effect.  Simply stated EXAIR’s highly engineered, intelligent designs entrain (combine) ambient air with the compressed air supply which saves you money!

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EXAIR Super Air Nozzle entrainment

EXAIR also offers the Ultra Sonic Leak Detector.  Simply point the device at a suspected leak which are typically found at unions, pipes, valves and fittings from up to 20’ away.   Plants that are not maintaining their plumbing can waste up to 30% of their compressors output through undetected leaks.

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EXAIR Ultra Sonic Leak Detector

EXAIR has a complete optimization product line that the Ultra Sonic Leak Detector is in that includes the Electronic Flow Control, Digital Flowmeter’s and a Digital Sound Level Meter.  All designed to either increase the safety or efficiency of your compressed air usage.

EXAIR has 15 other product lines all designed to increase your process efficiency and save you money by using you compressed air supply efficiently.  Why not visit the EXAIR website or call and request a free catalog?

When you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition

Super Air Nozzles and Stay Set Hoses to Replace Open Tubes

I recently worked with an company that performs energy audits and they were working with a food company to review and propose ways to reduce the energy consumption throughout the plant. One area where we were able to help was on an onion peeling machine, shown below:

Vegetable Peeler Wide
Onion Peeler With Screw Conveyor and Blow off Tubes

The area of machine in question used a screw conveyor and friction source to help loosen the peels and fifteen (15) 1/4″ O.D. open ended tubes, which were noisy and unsafe, to blow the peels completely off and away form the onion. The auditor was able to install an air flow meter on the system and found that the machine was consuming 220 SCFM of compressed air for this operation.

Vegetable Peeler Detail
(15) Total, 1/4″ Tubes Used to Blow Air and Help Remove the Peels

We proposed to replace the tubes with a 6″ Stay Set Hose and the model 1103 Mini Super Air Nozzle.  Each model 1103 Mini Super Air Nozzle will consume just 10 SCFM of 80 PSIG compressed air. Attached to the 6″ Stay Set Hose, the nozzle can be placed exactly where needed and aimed appropriately. A strong blast of air rated at 0.56 lbs (9 ozs.), and ultra quiet at 71 dBA, the Mini Super Air Nozzle delivers the results needed.

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Model 1103 – Mini Super Air Nozzle

1103 Performance

1103 Pattern

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Model 9256 6″ Stay Set Hose

The Stay Set Hose has “memory” and will not creep or bend, simply install the 1/4 NPT fitting into the compressed air supply side, an thread the 1/8 NPT Mini Super Air Nozzle into the other end and position as needed!

Fifteen (15) of the Mini Super Air Nozzles will pass 150 SCFM of compressed air compared to the current usage of 220 SCFM, resulting in a 70 SCFM drop, or a 31.8 % reduction.  At a typical cost of $0.25 per 1000 Cubic Feet of Compressed Air, the nozzles would save $1.05 per hour of operation. Rate of Return yields a full pay-off in just 43 days of operation (24 hours per day operation)!

If you are looking for ways to save on compressed air usage in your facility that is safe to operate and quiet to use, we will have a solution for you.

If you have questions about any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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