Supporting The Next Generation of Engineers

A while back, I was lucky enough to spearhead a donation from EXAIR to The University of Cincinnati’s 1819 Innovation Hub Makerspace. For the past several years, we have been sponsoring the UC Combat Robotics club, which uses the Makerspace to build its bots and learn more about the applications of its course of study. This facility is open to all students who attend the university. The course of study does not matter; the desire to learn appropriate usage of equipment and a determination to create are all that is needed.

The space puts every student through training for safety and manufacturing processes, if needed, and then the students can operate on their own. The staff in the space are often students themselves, or they are people with years of industry experience to share with the students utilizing the space. This 12,000 square-foot makerspace and fab lab is home to a variety of equipment that can all be seen on their equipment listing here. You can go in and learn how to use anything from a sewing machine or soldering iron, all the way up to a 4-axis CNC machine. If you just have an idea and desire to learn, the staff will even train you on how to make the idea come to life and do it all safely in a semi-controlled environment.

When we saw the need for safe, efficient use of compressed air in this space, EXAIR stepped in to help. We outfitted every air drop in the facility and every machine with an EXAIR VariBlast Precision Safety Air Gun w/ Chip Shield and Nano Super Air Nozzle. This will help keep all the operators safe by eliminating the risk of exceeding 30 psig dead-end pressure and also reducing the operating noise level to below the OSHA standard of 85 dBA, all the way down to 75 dBA. By keeping the entire facility uniform, they are also able to make purchasing new units easier when they are needed.

We also helped them assemble their new EXAIR Chip Trapper System to help recycle the coolant from their CNC machines and help them extend the life of their cutting fluid by being able to remove all the debris from their sumps, reducing the surface area on which bacteria can grow.

On top of both of these, we helped them to see how easy a Cold Gun is to mount onto the side of virtually any machine in their shop, even the industrial sewing machine, and showed them just how beneficial it can be. There was actually a group of students using one of the stationary belt sanders, and we were able to connect the Cold Gun to the closest air drop, use the magnet to hold it onto the housing of the sander, and position the single-point cold outlet to the contact point to keep the sandpaper and material cooler to prevent loading up of the sandpaper.

These were just a couple of the products we were able to share with them in order to help outfit their space with safe and efficient compressed air products. I’ve condensed the entire event down into a 50-second clip if you would like to watch. I feel like we need some classic Benny Hill music in the background.

I think the best part of this experience for me was the discussion that evolved as we unpacked all the items. We had already had lots of chatter back and forth around what their system is capable of and also what they plan to do with the EXAIR products. Then, as we are unpacking and discussing the capabilities, more applications started to come up. I have a feeling this is just part of what happens in this space. Ideas are born, then brought into fruition, all within these walls.

Special thanks to Benjamin Jones and his team for letting us be part of training the future leaders in the industry.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Step 3: Upgrade Your Blow off, Cooling, and Drying Operations

In the world of manufacturing, compressed air is often called the “fourth utility.” It’s essential, but it’s also expensive to produce. If you’re following the Six Steps to Optimize Your Compressed Air System, Step 3 is where you stop the bleeding.

Step 3, dear reader, is the subject of today’s blog.

Upgrading your blow-off, cooling, and drying operations from “homegrown” solutions to engineered products is one of the fastest ways to slash energy costs and improve plant safety.

The Problem with “In-House” Solutions

Many plants rely on makeshift blow-off devices: crimped copper tubes, pipes with drilled holes, or basic air nozzles found at a hardware store. While they seem “free” or cheap, they are incredibly inefficient.

  • High Air Consumption: They lack the physics to move air efficiently, requiring massive volumes of compressed air to do the job.
  • Dangerous Noise Levels: Drilled pipes produce a high-pitched shear that often exceeds OSHA noise exposure limits.
  • Safety Hazards: If a pipe or open tube is dead-ended against skin, it can lead to serious injury or air embolism.

The Engineered Solution: EXAIR Technology

This is where EXAIR engineered compressed air products change the game. Unlike a standard pipe, EXAIR products use the Coanda effect to “entrain” the surrounding room air. For every part of compressed air used, an EXAIR nozzle or air knife pulls in 30 to 40 parts of “free” ambient air.

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.

If you are drying a conveyor belt or cleaning wide sheets of material, a drilled pipe is a money pit. An EXAIR Super Air Knife provides a high-velocity, uniform sheet of air across the entire surface. It’s quiet (around 69 dBA for most applications) and reduces air consumption by up to 80% compared to open headers.

For targeted blow-off or part ejection, Super Air Nozzles replace open tubes and cheap nozzles. They provide a forceful, concentrated stream of air while meeting OSHA requirements for skin pressure and noise. You get more “push” for significantly less “psi.”

Step 3 isn’t just about blowing air; it’s about optimizing how air manages temperature and waste. From Vortex Tubes that provide spot cooling without refrigerants to Air Amplifiers for smoke and fume removal, these tools ensure you aren’t overworking your compressors for simple tasks.

The Bottom Line

Upgrading to EXAIR engineered products isn’t just a maintenance fix; it’s a financial strategy. Most facilities see a return on investment (ROI) in just weeks through reduced energy bills.

By replacing inefficient, loud, and dangerous blow-off methods with engineered solutions, you’re not just optimizing your compressed air—you’re creating a quieter, safer, and more profitable shop floor.

Al Wooffitt
Application Engineer

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On Demand Ionization with the Gen4 Ion Air Jet

Static can be a big issue, whether it is shocking operators, causing jamming of machines, or collection of dirt and debris. This is especially true in the colder months. At EXAIR we have a wide range of Static Eliminators that can handle just about every static problem. However, sometimes the issue can be concentrated in smaller areas, and the solution needs to be more precise. For these types of situations, our Gen4 Ion Air Jet is perfect.

The Gen4 Ion Air Jet is a combination of our High Velocity Air Jet, and our Gen4 Ionizing Point. The Air Jet generates a high-speed air stream using a specially designed Coanda profile. This design creates a low pressure at the Air Jet’s entrance, allowing it to pull in surrounding air at a ratio of 5:1. As a result, the Air Jet operates efficiently, producing more ambient air in its output than compressed air. Additionally, thanks to the engineered design, they produce a smooth laminar air stream that can treat a surface up to 15 feet away.

Due to the laminar nature of the airflow, the ions generated by the Ionizing Point will be carried by the air stream all the way to the targeted area. When operated at a pressure of 80psig, the Ion Air Jet is capable of dissipating a 5kV charge in under 0.18 seconds. Although for more sensitive applications, the pressure can be regulated down to adjust the airflow from a blast to a breeze.

Ion Air Jet

In addition to being efficient in its use of compressed air, the Ion Air Jet boasts several other advantages. Due to the engineered design of the High Velocity Air Jet, and the laminar airflow produced, the Ion Air Jet is very quiet compared to other compressed air blow off options. At 82dBA (when operated at 80psig), the Ion Air Jet is well below OSHA’s allowable noise level. It also meets OSHA’s dead-end pressure requirements.

The Ionizing Point used in the Ion Air Jet takes advantage of a shockless design, so it is safe to handle while in operation. As it utilizes the corona discharge method, there are no radioactive materials needed to produce the static neutralizing ions.

In addition to our standard Ion Air Jet Kits, we also have systems that combine our Ion Air Jet with our Stay Set Hoses, making hands-free operation even easier. Whether you are looking for a new solution, or looking to upgrade an existing process, give us a call and see if our efficient, low-cost Ion Air Jets can help solve your static issues.

Al Wooffitt
Application Engineer

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Accessories for Your Compressed Air Products

Here at EXAIR we are very proud of our Intelligent Compressed Air Products. We have spent a lot of time discussing their many benefits, including their efficiency, the fact that many have no moving parts, little to no maintenance, meeting or exceeding OSHA safety standards for noise or dead end pressure. One thing we don’t talk as much about is the accessories that go along with and complement our products. Several of these accessory items are the reason why our compressed air products can boast about having little to no maintenance, or reduced noise levels. In this blog I want to cover some of these unsung heroes.

From left to right, a few value-added accessories for your Vortex Tube: Hot Muffler, Cold Muffler, Automatic Drain Filter Separator, Oil Removal Filter, and Solenoid Valve/Thermostat Kit.

Some of the most popular accessories we offer are our compressed air Filters and Regulators. We suggest using these with all our products (or even with ones that aren’t ours).

The Filter Separator is designed to remove moisture, dirt, and rust from your compressed air system. The 5-micron filter element ensures that contaminants don’t clog or harm your compressed air equipment.

An Oil Removal Filter (which should always be installed after our Filter Separator) provides even more precise filtration by getting rid of oil and solid particles with a 0.03-micron element.

Our Pressure Regulators let you choose the operating pressure. At EXAIR, we always advise running at the lowest pressure necessary to complete the task. Pressure Regulators help you achieve that, reducing unnecessary air usage and fine-tuning the performance of EXAIR products for your specific application.

We have some accessories designed specifically for certain products. For our Line Vacs, there’s the Line Vac Hose. You can also find Thermostats and Solenoid Valves that work great with our Cabinet Coolers, and if you’re using Vortex Tubes, we suggest checking out our Mufflers.

When it comes to our Air Knives, we offer a variety of fantastic options:

If you’re looking for a simple and dependable way to mount your Air Knife, our Universal Air Knife Mounting System is just what you need.

If your project needs something longer than our stock Air Knives, or if you want to manage different sections of the air flow separately, our Coupling Bracket Kits are ideal.

And if you want to simplify the plumbing for your Air Knife, don’t miss our Air Knife Plumbing Kits. They’re suitable for all Air Knives that are longer than 24 inches.

If you’re looking for plumbing options, we’ve got a range of compressed air hoses and fittings that will simplify things for you.

Our Coiled Hoses work great with our Safety Air Guns, giving you more freedom of movement while you work.

Our Compressed Air Hoses are often used alongside our Industrial Housekeeping products to provide the necessary reach for the drum and dolly.

Finally, if you’re looking for a way to mount or position your Air Nozzles, check out our Magnetic Bases, Stay Set Hoses, and Swivel Fittings that can help create a complete setup.

No matter what your application requires or the product you need, we’ve got a variety of complementary accessory products that will simplify installation and adjustments. If you have any questions about these or any other EXAIR products, don’t hesitate to reach out to us.

Al Wooffitt
Application Engineer

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