Benefits of Engineered Air Jets and Nozzles

EXAIR’s Engineered Air Nozzles and Air Jets provide a superior solution to minimize compressed air usage and reduce noise levels for compressed air blow-off operations.

Air Nozzles and Jets – when compared to commonly used open copper tubes or pipes the compressed air savings can be as high as 80%. With less compressed air, sound levels are greatly reduced.  A 10 dBA noise level reduction is typical.  All EXAIR Air Nozzles and Jets meet OSHA guidelines for dead end pressure and sound level exposure standards.
EXAIR Air Jets

EXAIR Nozzles and Jets are designed and manufactured to take advantage of the Coanda (wall attachment of a high velocity fluid) effect which can amplify the airflow up to 25 times. The compressed air exits through the small holes on the nozzle which entrains the surrounding air. The effect from this is a high volume, high velocity blast using less compressed air.  EXAIR manufactures many sizes and styles of air nozzles from the smallest, but quite powerful M4 x 0.5 thread Atto Super Air Nozzles to our largest 1-1/4 NPT Super Air Nozzle.  We also offer Flat Super Air Nozzles, and the Back Blow style nozzle for cleaning out tubes, pipes, channels or holes from 1/4″ to 16″ in diameter.

The Air Jets are 1/8 NPT threads and blow air out at a right angle from the inlet. They produce a vacuum on the larger diameter side which pulls in surrounding ambient air into the total output flow. Air Jets are available in brass or Type 303 stainless steel. You can choose from a fixed flow style or an adjustable flow style to provide flexibility for your applications. The adjustable flow models have a clear micrometer air gap indicator to assure consistent and accurate results.

All of our Air Nozzles and Jets  are engineered to meet or exceed OSHA Standard 1910.24(b) for 30 PSIG dead end pressure, they cannot be dead-ended as there is always a route for the air to escape. In addition, our products are going to meet the OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels.

EXAIR’s Flat Super Air Nozzles have been blowing away the competition since 2003.

EXAIR’s Swivel Fittings make it easy to adjust the position of the Air Nozzles and Air Jets.  The fittings allow for movement of 25° form the center axis for a total movement of 50°.  There are nine different models available and all of them are made from stainless steel

EXAIR Swivel fittings

If you would like to discuss blow off, noise levels, dead end pressure or any of EXAIR’s Intelligent Compressed Air® usage solutions, I would enjoy hearing from you…give me a call.

Jordan Shouse
Application Engineer

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Improve Noise Exposure with EXAIR Flat Super Air Nozzles

EXAIR manufactures a variety of nozzles that are OSHA safe, high quality, and very efficient.  They are engineered to entrain the “free” ambient air into the air stream to create a powerful force while reducing compressed air usage.  Thus, saving you money.  With a multitude of blow-off applications like clearing small holes to quickly cleaning gantries on CNC tables, EXAIR has the nozzles for you.  In this blog, I will discuss the features and benefits of the EXAIR Flat Super Air Nozzles.    

The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air.  Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise.  They come in two widths; 1” (25mm) and 2” (51mm).  EXAIR offers a standard Flat Super Air Nozzle and a High Power Flat Super Air Nozzle in two different materials, zinc-aluminum alloy and 316 stainless steel.  And with a metal construction, breakage is not a concern and performance are not sacrificed even in the harshest of environments. 

The unique patented shims used with the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function.  First, they come in different thickness to create a wide range of forces.  In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a blast without overusing your air compressor.  The patented shim also allows an even flow across the entire width of the air nozzle.  Unlike the plastic flat nozzles that use holes which generates a fluctuation of forces across the width.  Lastly, they help to entrain the free ambient air; so that less compressed air is required.  The high efficiency design will save you money.  The EXAIR Flat Super Air Nozzles are effective in uniform blowing with safety and efficiency in mind. 

To expand more on safety, I will direct you to Noise.  With “open” holes in nozzles, the compressed air is turbulent and loud.  The National Institute for Occupational Safety and Health, NIOSH, states that 70% to 80% of all hearing loss within a manufacturing plant is caused by compressed air.  OSHA created a chart to show the maximum allowable noise exposure.  This chart shows the time and noise limits before requiring hearing protection.  The EXAIR Flat Super Air Nozzles are designed to have laminar flow which is very quiet.  As an example, the model 1122 2” Flat Super Air Nozzle has a sound level of only 77 dBA at 80 PSIG (5.5 bar); well under the noise exposure limit for 8 hours.   

With the EXAIR Flat Super Air Nozzles, you can take advantage of the durability, safety, and efficiency for your blow-off devices.  With automated systems, or machine builders, you may want to look at the EXAIR brand for your blow-off, cooling, and coating applications.  The overall cost of your system as compared to the cost of the nozzles should not warrant the use of poor-quality plastic nozzles to save a couple of dollars.  Because in the long run, it will actually cost you more with loss of production, compressed air waste, very loud noises, and unsafe work environments. 

EXAIR stocks these nozzles for quick delivery.  If you are within the U.S. or Canada, they come with a 30-day unconditional guarantee to try them out.  If you need any help with our Flat Super Air Nozzles or how to build an optimum blow-off system, you can speak to an Application Engineer at EXAIR.  We will be happy to assist you. 

John Ball
Application Engineer
Twitter: @EXAIR_jb

Save Your Compressed Air Today with These Simple Methods

When discussing ROI, return on investment, for an industrial compressed air system it is necessary to  understand what it costs to produce compressed air.  Generally we calculate that it costs .25 cents to produce 1,000 SCF (Standard Cubic Feet) of compressed air here in the Midwest of the United States. For our example let’s consider a typical 250 HP industrial compressor running 24 hours per day/5 days per week for 52 weeks.  This compressor can generate 374,400,000 SCF per year, using the industry standard utility cost for the Midwest of .25 cents per 1,000 SCF it will cost $93,600 to produce that volume of compressed air.

To avoid wasting money on compressed air generation it is extremely important to eliminate unintended or wasteful compressed air use in your plant. The two main offenders are leaks and open tube blow-offs.  While soapy water is a good method for discovering leaks, EXAIR offers the Ultrasonic Leak Detector.  This handy device allows leaks to be detected at distances of up to 20′ away! Also consider how safe and convenient it is to find leaks in overhead pipes while standing on the ground instead of on a ladder. Using a tool like this to do an entire system leak audit can easily result in many small leaks being identified and when fixed result in a large savings.

open tubes
Thirteen Open Tube Blow-Offs

Now let’s look at what an open pipe or tube may consume. A single 1/4″ OD copper tube can use 33 SCFM @ 80 PSIG inlet pressure.  Using the manifold pictured above as our example with 13 open tubes, each tube can consume 33 SCFM @ 80 PSI inlet pressure. With 13 open tubes running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of  160,617,600 SCF annually.  If we installed the EXAIR model 1100 Super Air Nozzle  using a simple compression fitting we would reduce the air consumption dramatically.  The EXAIR 1100 Super Air Nozzle consumes 14 SCFM @ 80 PSIG inlet pressure, running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 68,140,800 SCF annually.  That change will save you 92,476,800 SCF annually which is equal to $23,119.20 and 24.7% of air compressor capacity!  These calculations are all based on continuous running applications, if intermittent operation is possible consider the EXAIR Electronic Flow Control for even greater savings.  The EXAIR Electronic Flow Control combines a photoelectric sensor with timing control that limits compressed air use by turning it off when no part is present

Open pipe blow offs also violate OSHA standard 29 CFR 1910.242(b) requirement for using compressed air for cleaning when pressurized above 30 PSIG. Not to mention they generally are louder than 90 dBA, which is the maximum allowable noise exposure without hearing protection under OSHA standard 29 CFR – 1910.95 (a). The EXAIR engineered Super Air Nozzle is a great way to avoid a OSHA fine.

A great product that will help you keep your fingers on the pulse of compressed air consumption and demand is by incorporating the EXAIR Digital Flow Meter.  This handy item mounts directly to the pipe.  The digital display shows the amount of compressed air being used in any leg of your distribution system.  The Digital Flow Meter is offered in sizes for 1/2″ – 4″ Schedule 40 Iron Pipe and 3/4″ – 4″ Copper Pipe.  It also is available with the Summing Remote Display that is prewired with a 50′ cable, it is powered by the Digital Flow Meter and with a push of the button will display either the current compressed air consumption, consumption for the previous 24 hours or the total cumulative usage.

The Digital Flowmeters are also available with wireless capability using the ZigBee mesh network protocol, data can be passed from meter to meter to extend the distance over which the wireless system can operate.  Each meter has a range of up to 100′ (30 meters). Or you can opt for the USB Data Logger option.  The USB Data Logger can store approximately 9 hours of readings if set to sample once every second or up to 2 years if sampled every 12 hours.

If you would like to talk about any of the quiet EXAIR Intelligent Compressed Air® products or our line of Optimization Products, feel free to contact me or any EXAIR  Application Engineer.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Two Important Safety Factors When Choosing Air Nozzles

At EXAIR, we have a statement, “Safety is everyone’s responsibility”.  And we also manufacture safe compressed air products.  In the United States, we have an organization called Occupational Safety and Health Administration, OSHA, that enforces directives for safe and healthy working environments.  They do training, outreach programs, and educational assistance for manufacturing plants.  They will also enforce these directives with heavy fines for violations.  The two most common violations with compressed air are air guns and blow-off devices are described in 29CFR 1910.242(b) for dead-end pressure/chip shielding and 29CFR 1910.65(a) for maximum allowable noise exposure.

Here is an example of a nozzle that is dangerous.  As you can see, there is only one opening where the air can come out from the nozzle.  Other types of nozzles that would fall into this same group would include copper tube, extensions, and open pipes.

Unsafe Nozzle

They are dangerous as the compressed air cannot escape if it is blocked with your body or skin.  If operated above 30 PSIG (2 bar), these nozzles could create an air embolism within the body which can cause bodily harm or death.  This is a hazard which can be avoided by using EXAIR Super Air Nozzles and Safety Air Guns.  The nozzles are designed with fins which allows the air to escape and not be blocked by your skin.  So, you can use the EXAIR Super Air Nozzles safely even above 30 PSIG (2 bar).

Unsafe Air Gun

To counteract the dead-end pressure violation, some nozzle manufacturers create a hole through the side of the nozzle (Reference photo above).  This will allow for the compressed air to escape, but, now the issue is noise level.  With an “open” hole in the nozzle, the compressed air is very turbulent and very loud.  The National Institute for Occupational Safety and Health, NIOSH, states that 70% to 80% of all hearing loss within a manufacturing plant is caused by compressed air.  OSHA created a chart to show the maximum allowable noise exposure.  This chart shows the time and noise limits before requiring hearing protection.  The EXAIR Super Air Nozzles, Super Air Knives, Super Air Amplifiers are designed to have laminar flow which is very quiet.  As an example, the model 1210 Safety Air Gun has a sound level of only 74 dBA; well under the noise exposure limit for 8 hours.

Hearing loss is the best known, but not the only, ill effect of harmful noise exposure. It can also cause physical and psychological stress, impair concentration, and contribute to workplace accidents or injuries.

NIOSH created an overview of how to handle hazards in the workplace.  They call it the Hierarchy of Controls to best protect workers from dangers.  The most effective way is by eliminating the hazard or substituting the hazard.  The least effective way is with Personal Protective Equipment, or PPE.  For unsafe compressed air nozzles and guns, the proper way to reduce this hazard is to substitute it with an engineered solution.

One of the last things that companies think about when purchasing compressed air products is safety.  Loud noises and dead-end pressure can be missed or forgotten.  To stop any future fines or additional personal protective equipment (PPE), it will be much cheaper to purchase an EXAIR product.  And with the Hazard Hierarchy of Controls, the first method is to remove any hazards.  The last method for control is to use PPE.  In the middle of the hierarchy is for an engineered solution.  EXAIR products are that engineered solution.  If you would like to improve the safety in your facility with your current blow-off devices, an Application Engineer can help you.

John Ball
Application Engineer
Twitter: @EXAIR_jb

Picture:  Safety First by SuccoPixabay License