Don’t Forget About Operating Cost: How To Calculate Return On Investment

If you have a stock portfolio, or even a retirement account, you’ve likely heard the term “return on investment.” It basically tells you how hard your money is working for you, and, the higher, the better.

The term is also used to determine the financial benefits associated with the use of more efficient products than you’re using right now:

  • The cost of operating industrial pumps, air compressors, and a variety of industrial rotating equipment, can be greatly reduced by using variable frequency drive systems that sense the demand and change the motor’s speed (and hence power consumption) accordingly.  These systems are not cheap, but the reduction in operating costs is often quite noticeable.
  • At home, installing energy efficient windows (spoiler alert: your builder probably used the cheapest ones he could find…mine sure did) or upgrading appliances & HVAC can cost a pretty penny, but you’ll also see your electric bill go down.

EXAIR Corporation has a worldwide reputation for providing highly efficient compressed air products for industry.  Our Engineering Department has a company-wide reputation for being data fanatics…which is key to allowing us to provide our customers with ample information to make the best choices to optimize your use of your compressed air.

It’s not hard at all to calculate your potential savings from the use of an engineered compressed air product, assuming you know how much air your current device is using.  If not, we can tell you if you can send it in for Efficiency Lab testing (free and fast; call me to find out more.)  Here’s an example for a VERY typical situation: replacing an open copper tube blow off with an EXAIR Super Air Nozzle:

  • A 1/4″ copper tube uses 33 SCFM @80psig
  • A Model 1100 Super Air Nozzle uses 14 SCFM @80psig

33 SCFM X 60 min/hour X 8 hours/day X 5 days/week X 52 weeks/year = 4,118,400 SCF

14 SCFM X 60 min/hour X 8 hours/day X 5 days/week X 52 weeks/year = 1,747,200 SCF

4,118,400 – 1,747,200 = 2,371,200 Standard Cubic Feet of compressed air savings

If you know your facility’s cost of compressed air generation, you can calculate the monetary savings.  If not, we can get a good estimate via a thumbrule used by the U.S. Department of Energy that says it typically costs $0.25 to generate 1,000 SCF of compressed air:

2,371,200 SCF X $0.25 ÷ 1,000 SCF = $592.80 annual monetary savings

In 2019, the cost of a Model 1100 Zinc Aluminum Super Air Nozzle is $41.00.  Daily savings (not counting weekends) is:

$592.80 ÷ 260 days (5 days/week X 52 weeks/year) = $2.28 daily savings

Meaning the payoff time for the $41.00 investment in the Model 1100 is:

$41.00 ÷ $2.28 = 17.9 days

Or…just over three weeks.  Now that I’ve shown you the math, I’d like to introduce you to the EXAIR Cost Savings Calculator.  Just enter the data, and it’ll check your math (because I know you’re going to do the math anyway, just like I would.)  It even does the ROI for you too.

Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice. Does the one on the right look familiar?  It’s literally the example I used for the above calculations.

If you’d like to find out more about how – and how fast – EXAIR Intelligent Compressed Air Products can pay off for you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Durable, Versatile, and Efficient – EXAIR Soft Grip Safety Air Gun

As compressed air technology advanced through the 20th Century, its uses multiplied.  Pneumatic cylinders became common for rolling and forming presses.  The convenience and portability of powerful pneumatic hand held tools spread in assembly and manufacturing facilities.  Along the way, operators also found that an open-ended compressed air line could be used for quick and easy blow off in a number of applications. There were, however, some pretty risky safety issues associated with this.

In December of 1970, the Occupational Safety & Health Act became the law of the land, and in 1971, the Occupational Safety & Health Administration (OSHA) was created.  Among the many hazards in workplaces they targeted was compressed air use for cleaning.  The primary concerns were:

  • An open ended blow off could inadvertently be dead ended onto a person’s body, and if the pressure were high enough, it could break the skin and cause a deadly condition called an air embolism.  So they limited the outlet pressure to 30psi.
  • Blowing something off with air can (and usually does) result in airborne particulate traveling at a high velocity that can imbed in your skin or in your eye.  So they mandated the use of proper chip guarding, protective clothing, and eye protection.

This is where the history of the safety air gun begins.  Through the 1970’s & 1980’s, engineers rolled out product after product conforming with these new safety standards, sometimes looking for economy, sometimes efficiency…and occasionally, both.

It’s not hard to make a blow off nozzle that complies with OSHA’s dead end pressure requirement; you just need to provide a path for the air to escape in case the nozzle end is blocked.  Cross drilled nozzles (shown at right) are simple, cheap, and OSHA compliant, but they’re also loud & inefficient.

EXAIR’s Super Air Nozzles not only protect against injury from dead ended high pressure air, their engineered design also makes them quiet, and efficient.  They are commonly installed on the Soft Grip Safety Air Gun.  Along with our Chip Shields (shown at right) and your personal protective equipment, you get OSHA compliance, AND lower air consumption & noise levels.

With the Soft Grip Safety Air Gun, you also get a diverse range of options to suit the specific needs of numerous applications:

If you’re looking for a hand held blow off device, your choices are many.  If you’re looking for a quiet, efficient, safe, and versatile one, your choice is easy:  the EXAIR Soft Grip Safety Air GunCall me and we’ll figure out which one you need.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

What’s So Great About The VariBlast Compact Safety Air Gun?

Well, for one thing, it’s won ANOTHER award…in addition to the 2018 Plant Engineering Product of the Year (Silver Award, Compressed Air Category) for 2018, it’s now won the 2019 Industrial Safety & Hygiene Reader’s Choice Award.

But we didn’t need awards to tell us how great they are.  EXAIR Corporation has 35 years of continuously improving experience in the design, engineering, and manufacture of quiet, safe, and efficient compressed air products for industry.  The VariBlast Compact Safety Air Guns are just another innovation that’s come to fruition, courtesy of the knowledge, experience, and dedication to quality from our R&D Engineering & Production departments.

Whatever your needs are, EXAIR has a Safety Air Gun for you.

But you don’t have to take OUR word for it: a satisfied customer base has proven the VariBlast Compact Safety Air Gun‘s success:  We offer a 30 Day Unconditional Guarantee on any catalog product.  That means you can put it through its paces for up to a month…if it’s not going to work out, for any reason, we’ll arrange return for full credit.  Of the dozens of VariBlast Safety Air Guns we’ve sold every month for the last two years or so, we have not had one returned.  Not. One.  To which I say: no wonder…check it out:

If you’re looking for an economical, efficient, quiet, variable flow, handheld blow off solution, look no further than the VariBlast Compact Safety Air Gun…just another award winning Intelligent Compressed Air Product, brought to you by EXAIR.  To the readers of Industrial Safety & Hygiene Magazine…thanks for noticing!

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Engineered Air Nozzles vs. Commercial vs. Open Air Line

How much does your compressed air cost?  If you don’t know, there are some handy tools, like this one, that will help you calculate it precisely.  For estimating purposes, the U.S. Department of Energy estimates that compressed air costs about $0.25 per 1,000 Standard Cubic Feet of mass to generate.  Again, this is an estimate based on different electric power consumption costs from around the country, varying efficiencies of different types & sizes of air compressors, etc., so, as the automobile folks say, “your mileage may vary.”

Regardless of whether you calculate it exactly or just estimate it, it’s going to come as no surprise that it isn’t cheap.  That’s why efficient use HAS to be taken seriously.  Luckily, there are steps you can take (six, specifically, see below,) that can help.

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

This is a common inquiry here at EXAIR Corporation.  It’s not hard to find a blog about them -like this one, or this one, or even this one.  Before we go any further….yes, this is ANOTHER one.

I recently had the pleasure of helping a caller who was using the male ends of pneumatic quick connect fittings to blow off steel tubes:

Cheap and easy…but loud & wasteful. Don’t let this happen to you.

They were operating these, for the most part, 24/7, as their production was continuous, although there were actually spaces between product at times.  They were using over 74 SCFM…that’s 750,000 Standard Cubic Feet of compressed air PER WEEK, or over 39 MILLION SCF per year…over $9,700.00* in generation cost.  After a brief discussion, they ordered & installed two Model 1101 Super Air Nozzles, which threaded right in to their existing fittings:

This was a “slam dunk” – no system modification was even required.

Not only were the Super Air Nozzles markedly quieter (sound level went from 90dBA to 72dBA,) air consumption was reduced to just 20.90 SCFM…a 72% reduction, which translates to an annual cost savings of over $7,000.00*.  But wait…there’s more.

See, that was just “step 3” – they also installed a solenoid valve in the supply line, actuated from their process control.  This turns off the compressed air in between cycles, roughly estimated at about half the time.  This gets them additional savings of almost $1,400.00* per year.  But wait (again)…there’s STILL more.

This is one of five lines that were (mis)using the pneumatic fittings.  With the dramatic improvements of the first line, they ordered Super Air Nozzles for the remaining four.  So, to recap…an investment of $440.00 (2019 List Price for the Model 1101 is $44.00,) plus their solenoid valves, they’re saving almost $42,000.00* per year in compressed air generation costs.

*using the DoE thumbrule of $0.25/1,000 SCF referenced in the first paragraph.

Engineered compressed air products like the Super Air Nozzles are a clear winner all day, every day, over any open-end type device.  If you’d like to find out how much EXAIR’s Intelligent Compressed Air Products can save you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Another Spray Nozzle, Another Award

EXAIR Corporation’s Research & Development team often finds themselves at odds with our Marketing department, who thinks R&D, through their constant introduction of new ideas & products, is trying to turn our catalog into something resembling a phone book.

This mass of paper, my dear Millennial friends, was key to effective communications in the 20th Century.

I do not believe that is their aim or intention, though (and to be fair, Marketing doesn’t either.)  Honestly, we just want to help folks in a wide range of industries solve problems.  And a diverse range of engineered compressed air products is our tried-and-true, successful method for doing so.

Over the past few years, EXAIR has worked hard on expanding our line of Atomizing Spray Nozzles with different sizes, flow rates, and spray patterns to meet most any need for a fine, controllable liquid spray.  Most recently, our efforts were rewarded when our Model AT5010SS 1/2 NPT 360° Hollow Circular Pattern Atomizing Spray Nozzle earned recognition by Plant Engineering as a 2018 Product of the Year, in the Fluid Handling category.

If you need to spray liquid over a large area, this is the spray nozzle you’re looking for.  It can cover a 13 foot diameter with up to 150 gallons per hour.

Model AT5010SS 1/2 NPT 360° Hollow Circular Pattern Atomizing Spray Nozzles are ideal for smooth, even coatings in large pipe or duct ID’s, or for a mist or fog over a large area.

EXAIR Corporation offers a wide variety of Liquid Atomizing Nozzles, enough to fill a phonebook where we’re certain to have one that fits your spraying needs.  To find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Opportunities To Save On Compressed Air

If you’re a regular reader of the EXAIR blog, you’re likely familiar with our:

EXAIR Six Steps To Optimizing Your Compressed Air System

This guideline is as comprehensive as you want it to be.  It’s been applied, in small & large facilities, as the framework for a formal set of procedures, followed in order, with the goal of large scale reductions in the costs associated with the operation of compressed air systems…and it works like a charm.  Others have “stepped” in and out, knowing already where some of their larger problems were – if you can actually hear or see evidence of leaks, your first step doesn’t necessarily have to be the installation of a Digital Flowmeter.

Here are some ways you may be able to “step” in and out to realize opportunities for savings on your use of compressed air:

  • Power:  I’m not saying you need to run out & buy a new compressor, but if yours is
    Recent advances have made significant improvements in efficiency.

    aging, requires more frequent maintenance, doesn’t have any particular energy efficiency ratings, etc…you might need to run out & buy a new compressor.  Or at least consult with a reputable air compressor dealer about power consumption.  You might not need to replace the whole compressor system if it can be retrofitted with more efficient controls.

  • Pressure: Not every use of your compressed air requires full header pressure.  In fact, sometimes it’s downright detrimental for the pressure to be too high.  Depending on the layout of your compressed air supply lines, your header pressure may be set a little higher than the load with the highest required pressure, and that’s OK.  If it’s significantly higher, intermediate storage (like EXAIR’s Model 9500-60 Receiver Tank, shown on the right) may be worth looking into.  Keep in mind, every 2psi increase in your header pressure means a 1% increase (approximately) in electric cost for your compressor operation.  Higher than needed pressures also increase wear and tear on pneumatic tools, and increase the chances of leaks developing.
  • Consumption:  Much like newer technologies in compressor design contribute to higher efficiency & lower electric power consumption, engineered compressed air products will use much less air than other methods.  A 1/4″ copper tube is more than capable of blowing chips & debris away from a machine tool chuck, but it’s going to use as much as 33 SCFM.  A Model 1100 Super Air Nozzle (shown on the right) can do the same job and use only 14 SCFM.  This one was installed directly on to the end of the copper tube, quickly and easily, with a compression fitting.
  • Leaks: These are part of your consumption, whether you like it or not.  And you shouldn’t like it, because they’re not doing anything for you, AND they’re costing you money.  Fix all the leaks you can…and you can fix them all.  Our Model 9061 Ultrasonic Leak Detector (right) can be critical to your efforts in finding these leaks, wherever they may be.
  • Pressure, part 2: Not every use of your compressed air requires full header pressure (seems I’ve heard that before?)  Controlling the pressure required for individual applications, at the point of use, keeps your header pressure where it needs to be.  All EXAIR Intelligent Compressed Air Product Kits come with a Pressure Regulator (like the one shown on the right) for this exact purpose.
  • All of our engineered Compressed Air Product Kits include a Filter Separator, like this one, for point-of-use removal of solid debris & moisture.

    Air Quality: Dirty air isn’t good for anything.  It’ll clog (and eventually foul) the inner workings of pneumatic valves, motors, and cylinders.  It’s particularly detrimental to the operation of engineered compressed air products…it can obstruct the flow of Air Knives & Air Nozzles, hamper the cooling capacity of Vortex Tubes & Spot Cooling Products, and limit the vacuum (& vacuum flow) capacity of Vacuum Generators, Line Vacs, and Air Amplifiers.

Everyone here at EXAIR Corporation wants you to get the most out of your compressed air use.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

 

Airguns, OSHA, And You

Depending on the context, those may be three words you DON’T want to hear in the same sentence. Case in point…a caller I spoke with recently, who works at a large steel forging plant. During a recent inspection, management was surprised (and disappointed) to find out that, unbeknownst to them, some of their operators had modified some of their compressed air blow off devices.

These modifications left them in violation of both OSHA Standard 1910.242(b) (limit on outlet, or dead end pressure) and 1910.95(a) (limits noise level exposure.)  The OSHA inspector left them with an $8,000.00 fine, and a promise to return with an even higher one if the situation wasn’t corrected.

We discussed the ways their current devices were supplied, the conditions they were operating in, what they were used for…and why the operators had modified them.  Sadly, we found the devices were underperforming due to air supply issues – hoses that were too small in diameter and/or too long, with restrictive quick connect fittings.  And some of their modifications (drilling out the discharge) just exacerbated those problems.

Most of their applications were pretty typical – blowing flash, chips, oil, coolant, etc. from processed metal parts.  Typical enough that a couple of EXAIR Safety Air Guns would allow them to determine what they would need, by taking them around to various stations in the plant and trying them out.

My caller ordered a Model 1210 Soft Grip Safety Air Gun with a Zinc Aluminum Super Air Nozzle (our most popular for typical blow off applications,) and a Model 1260 Soft Grip Safety Air Gun with a High Force 1/2 NPT Zinc Aluminum Super Air Nozzle (the most powerful one available on the Soft Grip Safety Air Gun.)

Here’s Model 1210-6-CS, fitted with a Zinc Aluminum Super Air Nozzle on a 6″ Rigid Extension & Chip Shield.  All EXAIR Safety Air Guns are compliant with OSHA Standard 1910.242(b).

I feel pretty good about the chances of publishing a future blog about the success of this application.  If you want to keep up, I encourage to follow the EXAIR blog – there’s a link to the right to provide your email address – for more on this one, other applications, and a wealth of expert writings on how to get the most out of your compressed air system.

As always, if you’d like to discuss a particular compressed air application and/or product selection, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook