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
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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
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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
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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
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Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

capture.jpg
Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process and save you money, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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The Case For EXAIR Swivel Fittings

One of the more common questions we get here in the Application Engineering department at EXAIR is…

“What’s the best angle to position a Super Air Nozzle?”

The simple (and perhaps a little snarky, but I swear that’s not intended) answer is…

“The angle it takes to get the results you need.”

But wait, there’s more…we’re not going to leave anybody hanging like that. Many blow off applications are going to be best served by a “sweep” of air, at a low angle. That will be ideal for removing a light layer of dust from a relatively flat and smooth surface. A bit larger angle, relative to the surface, may be necessary if you need some impingement force to dislodge sticky, clumpy, or mildly adhesive debris.  Rarely will you want to blow directly, at a perpendicular angle, to a material’s surface.  An exception to this might be if you’re trying to remove excess moisture from a porous and thin material, like a web fiber.

Regardless of what angle you need to aim your Super Air Nozzle, there are several ways to do it.  You can use a compression fitting them onto bendable copper tubing…just don’t bend it too much or too often.  We’ve got Stay Set Hoses that allow for quick & easy repositioning…they come in lengths from 6″ to 36″, and are in stock.

EXAIR Stay Set Hoses and Swivel Fittings are ideal for installation and positioning of your Super Air Nozzle.

If you want to hold it in place firmly and securely, you’re looking for a Swivel Fitting.  They’re available for almost all of our Super Air Nozzles, from the Atto to the 1″ NPT Model 1114 High Force Super Air Nozzle.  They offer 50° of total movement, and are made of Stainless Steel for durability in most any environment.

EXAIR Swivel Fittings have male NPT threads on one end, and female NPT on the other.  The smaller Swivels, for the Atto, Pico, and Nano Super Air Nozzles, have M4x0.5mm, M5x0.5mm, and M6x0.75mm female threads, respectively, in the ball of the swivel itself for direct threading of these small Super Air Nozzles.

EXAIR’s Swivel Fitting Family

Swivel Fittings can also be used with a host of other EXAIR products.  In addition to the Super Air Nozzles, for example, they’ve historically been very popular with our Air Amplifiers.  Here’s a short informational video showing just how versatile they are:

EXAIR Intelligent Compressed Air Products are made to be easy to install & operate.  This is our intent from Research & Development, to Shipping & Receiving.  If you have questions, give me a call.  I want you to get the most out of our products!

Russ Bowman
Application Engineer
EXAIR Corporation
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