If you’ve ever cleaned around the house (and who hasn’t?), you’re probably familiar with atomized liquid spraying…it’s what happens when you squeeze the trigger on that bottle of cleaner that breaks down the stove top grease in the kitchen and the ring-around-the-tub in the bathroom.
There’s a variety of industrial and commercial applications that require an atomized liquid spray too…applications that are beyond the scope of an operator with a trigger-operated spray bottle. That’s where EXAIR Atomizing Spray Nozzles come in. We have three types: Internal Mix, External Mix, and Siphon Fed. Depending on what you want to spray, and how you want to spray it, one of these is likely going to work better than the others for you. Today, we’re going to examine the Internal Mix Atomizing Spray Nozzles.
Better mist: Because the liquid & air come together inside the air cap, this results in very fine atomization.
Range of adjustment: Regulating either the liquid or air pressure supply will change the flow rate AND the flow pattern, giving each individual nozzle a wide performance band. The needle valve can “fine tune” the flow and pattern with even greater precision.
Area of coverage: With five patterns (Narrow or Wide Angle Round, Flat Fan, Deflected Flat Fan, and 360° Hollow Circular) and 72 distinct models to choose from, you can get spray patterns from 2″ (1/8 NPT Narrow Round Model AN8010SS) to 13 feet (1/2 NPT 360° Hollow Circular Model AT5010SS.)
Flow rate: Again, because of the many models available, you can get from 0.6 gallons/hour (Model AN8010SS again) to 264 gallons/hour (1/2 NPT Wide Angle Round Model AW5030SS.)
No-Drip option: The standard Models have a needle valve, which, as mentioned above, gives you the ability to make minute changes to the flow rate & pattern. If the application calls for rapid on/off control, or the chance of an errant drip after flow is not stopped might be a problem, the needle valve can be replaced with a No-Drip assembly. This positively shuts off liquid flow, at the exit of the liquid cap, when air pressure is secured.
Easy installation: All of our Atomizing Spray Nozzles have female NPT (1/8, 1/4, or 1/2) ports. The 1/8 and 1/4 NPT models can be adequately supported – and positioned – with a Stay Set Hose, and all models (even the 1/2 NPT) can be used with an appropriately sized Swivel Fitting. If you want to use your own tubes or hoses, we’ve got “clip-in” style Mounting Brackets.
Interchangeability: The only difference between any model of the same-size Atomizing Spray Nozzle is the Liquid and/or Air Cap. If your application’s liquid spray requirements change, or vary, you don’t need to replace the whole nozzle; just one (or in some cases, both) of the caps.
I like some better than others, but I don’t believe I’ve ever had bad pizza. That’s why I was pretty excited when I got to talk to a caller from a popular pre-packaged pizza crust maker. When these crusts leave their oven, they spray a coating of seasoned oil on them. This not only flavors, but preserves the quality from the time they make & package them to the time I celebrate life with a tasty slice, right out of my oven.
They were using inexpensive liquid-only nozzles that led to an inconsistent application of the oil…sometimes too much; other times, too little. And, it was always spraying, even in between the individual crusts as they came down the conveyor, leading to wasted oil that had to be cleaned up later.
They were already familiar with our Super Air Nozzles, as they had several Model HP1125SS 2″ High Power Flat Super Air Nozzles in use for blowing off the packages prior to labeling, so the caller asked if we might have a solution for the oil too.
After considering the size of the crust and the distance at which they needed to install the nozzle, they decided to try a Model AF2010SS Internal Mix Flat Fan Pattern No-Drip Atomizing Spray Nozzle. This applies a consistent and even coating of oil, and, by feeding a signal from the oven controls into a solenoid valve in the compressed air supply line, they’ve eliminated the excess spray, leading to savings in material cost and cleanup time.
If you’d like to know more about how EXAIR Atomizing Spray Nozzles can save you time, mess, and liquid, give me a call.
In the world of compressed air blow off solutions, there are a number of options which customers must consider. Should the plant maintenance personnel configure something on-site? Is there a low-cost option available from a catalog warehouse? Or, is there an engineered solution available – and if there is, what does this even mean?
Ultimately, the exercise in comparing these options will help select the option best for the application and best for the company. In order to make these comparisons, we will consider each option based on the following attributes: Force, sound level, safety, efficiency, repeatability, and cost. These are the factors which impact the ability to perform as needed in the application, and effect the bottom line of the company
Blow off applications require a certain amount of force in order to perform the desired task. If the blow off is in a bottling line, for example, we will aim for a lesser force than if blowing off an engine block. But, no matter the application need, we will want to consider the ability of the solution to provide a high force, high impact blow off. Homemade and commercially mass-produced nozzles produce low-to-mid level forces, which translates to a need for more compressed air to complete a task. Engineered nozzles produce high forces, minimizing compressed air use.
Have you ever been to a concert and felt your hearing reduced when you left? This can be the case for personnel in industrial environments with unregulated noise levels. Homemade or non-engineered blow off solutions carry the risk of increased sound levels which are outside of the acceptable noise level limits. EXAIR engineered nozzles, however, are designed to minimize sound level for quiet operation and continual use.
Workplace safety is a serious matter for everyone from shop floor personnel to executive management. Whether you’re working with or near a compressed air operated device, or your making decisions for your company which have to do with the compressed air system, safety is undoubtedly a priority. Unfortunately, homemade and commercially available nozzles normally fail to meet OSHA standards for dead-end pressure requirements (OSHA Standard 29 CFR 1910.242(b)). This means that these solutions can pose a risk of forcing compressed air through the skin, resulting in an embolism which can cause severe harm or even death.
EXAIR nozzles, however, are designed to NEVER exceed dead-end pressure limits and to provide an escape path for airflow in the even the nozzle is blocked. This safety aspect is inherent in ALL EXAIR designs, thereby adding safety to an application when an EXAIR product is installed.
Compressed air is the most expensive utility in any facility. Energy enters as an electrical source and is converted into compressed air through a compressor where up to 2/3 of this energy is lost as heat. The resulting 1/3 of converted energy is then piped throughout a facility as compressed air, where up to 1/3 of the air is lost to leaks. With this in mind, maximizing the efficiency of a nozzle solution becomes imperative. A homemade solution or commercial nozzle does not maximize the use of the compressed air. The result is a need to increase flow or increase pressure, both of which result in higher energy costs.
EXAIR nozzles are designed for maximum force per CFM. This means that any of our nozzles will produce the highest force at the lowest possible compressed air consumption. This, in turn, reduces demand on the compressed air system and allows for a lower energy requirement. Less energy demand means less energy costs, which goes straight to the bottom line of your company.
When installing a nozzle solution, it is important to have the same force and flow from each unit. If a solution needs to be replicated, balanced, or adjusted in any way, having various forces and flows from a homemade setup will induce difficulty and could make changes impossible. Line speed or volume increases may not be possible due to variance in the output flow and forces from homemade setups, but an engineered solution will produce the same output every time. This means you can adjust the nozzles as needed to achieve the perfect solution in your application.
For many customers and businesses, the most important aspect of any solution comes down to cost. Will the solution work? And, how much does it cost? When it comes to a homemade or commercial blow off solution, it may or may not work, and it will have a low purchase cost. But, the purchase price isn’t the whole story when working with compressed air. The real cost of an item is in the operation and use. So, while a homemade solution will be cheap to make and install, it will be EXPOENTIALLY more expensive to operate when compared to an engineered solution. An excellent example is shown above. An open copper tube is compared to an EXAIR model 1102 Mini Super Air Nozzle. The copper tube cost only a few dollars to install, many times less than the EXAIR nozzle, but it costs almost two THOUSAND dollars more to operate in a year. Translation: Install a cheap blow off solution and pay for it in utility costs.
EXAIR nozzles and blow off solutions are engineered for maximum force, lowest possible noise level, OSHA safety compliance, maximum efficiency, and maximum repeatability. These factors allow for options which not only solve application problems, but also do so with the lowest total cost possible. If you have an application in need of a blow off solution, feel free to contact our Application Engineers. We’ll be happy to help. And, if your curious about the benefit of our products in your application, consider our Efficiency Lab. We will test your existing setup next to our recommended EXAIR solution and provide the impact to your bottom line.
I wrote a blog a few weeks ago about increasing efficiency with EXAIR Super Air Nozzles. In the application for that blog we used engineered nozzles to place open pipes, resulting in an efficiency increased of ~65%. This week’s installment of efficiency improvements boasts similar figures, but through the replacement of misused liquid nozzles rather than open pipe.
The image above shows a compressed air manifold with a number of nozzles. BUT, the nozzles in this manifold are not compressed air nozzles, nor do they have any engineering for the maximization of compressed air consumption. These are liquid nozzles, usually used for water rinsing.
In this application, the need was to blow off parts as they exit a shot blasting machine. When the parts exit the shot blasting process they are covered in a light dust and the dust needs to be blown away. So, the technicians on site constructed the manifold, finding the liquid nozzles on hand during the process. They installed these nozzles, ramped up the system pressure to maintain adequate blow off, and considered it finished.
And, it was. At least until one of our distributors was walking through the plant and noticed the setup. They asked about compressed air consumption and confirmed the flow rate of 550 m³/hr. (~324 SCFM) at 5 BARG (~73 PSIG).
The end user was happy with the performance, but mentioned difficulty keeping the system pressure maintained when these nozzles were turned on. So, our distributor helped them implement a solution of 1101SS Super Air Nozzles to replace these inappropriately installed liquid nozzles.
By implementing this solution, performance was maintained and system pressure was stabilized. The system stabilization was achieved through a 61% reduction in compressed air consumption, which lessened the load on the compressed air system and allowed all components to operate at constant pressure. Calculations for this solution are shown below.
Compressed air consumption of (9) model 1101SS @ 5.5 BARG (80 PSIG): 214 m³/hr. (126 SCFM)
Total compressed air consumption of 1101SS Super Air Nozzles:
Air consumption of 1101SS nozzles compared to previous nozzles:
Engineered air nozzles saved this customer 61% of their compressed air, stabilized system pressure, improved performance of other devices tied to the compressed air system, and maintained the needed performance of the previous solution. If you have a similar application or would like to know more about engineered compressed air solutions, contact an EXAIR Application Engineer.
EXAIR’s Engineered Air Nozzles and Air Jets provide a simple solution to lower compressed air usage and reduce noise levels for compressed air blowoff operations.
Why Air Nozzles and Jets – When compared to commonly used open copper tubes or pipes, compressed air savings can be as high as 80%. And with less compressed air, sound levels are greatly reduced. A 10 dBA noise level reduction is typical. All EXAIR Air Nozzles and Jets meet the Occupational Safety and Health Administration (OSHA) maximum dead end pressure and sound level exposure requirements. They also carry the CE mark.
EXAIR Nozzles are engineered to take advantage of the Coanda effect to amplify the airflow up to 25 times or more. Compressed air is ejected through the small orifices and surrounding air is entrained into the main stream. The resulting air stream is a high volume, high velocity blast of air at minimal consumption. EXAIR manufactures many styles, from the very small, but powerful Atto Super Air Nozzles, to the largest 1-1/4 NPT Super Air Nozzle. Also offered are 1″ and 2″ wide Flat Super Air Nozzles, and the Back Blow style for cleaning out tubes, pipes, channels or holes from 1/4″ to 16″ in diameter.
EXAIR Air Jets utilize the Coanda effect (wall attachment of a high velocity fluid) to produce air motion in their surroundings. A small amount of compressed air (1) is throttled through an internal ring nozzle above sonic velocity. A vacuum is produced, pulling in large volumes of surrounding, or ‘free’ air, through an around the jet (2). The exit flow is the combination of the two air sources (3).
EXAIR manufactures Air Jets in two types, High Velocity, and Adjustable with materials of construction of brass and Type 303 Stainless Steel. The High Velocity Air Jet uses a changeable shim to set the gap, controlling the force and flow of the air. The Adjustable does not use a shim, and has a micrometer gap indicator and locking ring to allow for varying force and flow performance.
If you have questions about Air Nozzles and Jets, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
They say time flies when you’re having fun. Maybe that’s why I found it a little hard to believe it’s been almost two years since we introduced the Back Blow Air Nozzles. They’ve become yet another “textbook” solution to a great many applications:
*Our Model 1006SS 1/4 NPT Back Blow Air Nozzlewon Plant Engineering Magazine’s “Product Of The Year” Bronze Award in 2015, and are successfully employed in a wide range of uses:
Blowing out splined bores by a gear manufacturer
Quickly cleaning out spindles between tool changes by a CNC machinery operator
Removing the last bits of powder from spent toner cartridges by a printing equipment recycler
*The Model 1008SS 1 NPT Back Blow Air Nozzleis becoming famous in hydraulic cylinder repair shops…after a cylinder bore is honed, one quick pass of the powerful blast it produces cleans bores from 2″ to 16″. We can even put it on the Model 1219SS Super Blast Back Blow Safety Air Gun, with a 1ft, 3ft, or 6ft extension.
If you want to see how they work, check out this video:
I could have sworn Lee Evans just made that video, but apparently, it’s over a year old now. Time does indeed fly, and I promise we’re having fun! If you’d like to find out more about how a Back Blow Air Nozzle – or any of our engineered compressed air products (old or new) – can make your operations quieter, more efficient (and hence, probably, more fun,) give me a call.
The EXAIR Super Air Knife is THE ideal, efficient, and quiet solution for most any blow off application. We know this for a fact; we’ve been making them for years, folks all around the world have been buying them for years, and they keep coming back for more. They’re popular enough that over the years, we’ve introduced Mounting Systems and Plumbing Kits for ease of installation, and when Coupling Kits (to join multiple Super Air Knives together for greater lengths) became big sellers, we “upped our game” and started making Super Air Knives up to nine feet (108″) long. And certain applications (I’m looking at YOU, lumber and paper industries) order multiples of THOSE, and our Coupling Kits. Quite literally, there’s no job too big for EXAIR Super Air Knives.
No matter how long they are, though, the laminar, high velocity curtain of air they generate only moves in one direction. So, if there are significant geometric features (holes, bosses, recesses, “nooks & crannies,” etc.) to be blown off, we’ll have to look at something supplemental.
Enter the EXAIR Blowoff Systems…it doesn’t get any easier than this: an EXAIR engineered Super Air Nozzle, attached to a flexible, repositionable Stay Set Hose, mounted to a Magnetic Base. Put a hard hitting, high velocity, pointed flow of air right where you want it. If the next piece is different, that’s no problem – just bend the hose to re-aim the air flow.
No matter what the requirements of your blow off application are, we have an efficient, quiet, and safe solution. If you’d like to find out more, give me a call.