If you’ve ever used an air gun to blow something off, you’re familiar with the cleaning ability of compressed air. If you can get the whole object blown off from where you’re standing, there really is no substitute…but what if you need to get to the other side…or sides?
This is where the EXAIR Super Air Wipe comes in…they allow you to blow a continuous, uniform 360° air stream, all around your product. Consider their benefits:
*Sizes: the Super Air Wipe’s compact ring design means it won’t take up a lot of room; you just need a few inches, in any direction, to install one. We stock them in eleven sizes, from 11″, all the way down to our brand-new 3/8″ diameter.
*Durability: All EXAIR Super Air Wipes are assembled with stainless steel shims and hardware. Models up to 4″ come with a rugged, stainless steel wire braided hose, connecting the two halves for compressed air supply.
*Ease of installation: Smaller sizes can be supported by the compressed air supply line, if a pipe is used and threaded into the connector hose’s 1/4 NPT port. Larger sizes can likewise be adequately supported with pipe to both halves. All models have a bolt circle of 1/4″-20 tapped holes for more permanent and rigid mounting. The split ring design is another key feature:
*Corrosion resistance: Depending on the environment in which the Super Air Wipe will be installed, we offer them with aluminum (3/8″ – 11″ sizes) or stainless steel (3/8″ – 4″ sizes) bodies.
*Temperature rating:Aluminum Super Air Wipes are good to 400°F (204°C) and stainless steel models are good to 800°F (427°C.)
*Range of operation: We install a 0.002″ thick shim in all stock Super Air Wipes; this is suitable for a wide range of typical industrial/commercial blow off applications…a Pressure Regulator can then be used to “dial in” the air flow precisely to meet specific needs. If a job calls for higher force & flow, additional 0.002″ shims can be installed. Shim Sets come with the Super Air Wipe Kits, or individual shims can be ordered separately.
*Performance: Before the Super Air Wipe, a ring of nozzles was commonly used. In fact, they still are, but we’re trying to fix that, at every opportunity we come across. Problem with those is, it’s hard to get an even air flow all around, which leads to inconsistent blow off. They can also be loud & inefficient, as we’ve found in numerous Efficiency Lab tests and Case Studies, like this one…
…and this one…
Do you have a challenging blow off application that you need help with? Call us to find out how an EXAIR Super Air Wipe (or another one of our Intelligent Compressed Air Products) can be a simple, quick & easy solution.
The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle. Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level. Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.
The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.
The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel. All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.
Also available, for extra blowing force, are the HP1125 and HP1125SS. The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.
Shim sets for any of the 2″ Flat Super Air Nozzles are available. The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″. For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.
As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle. If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well. Check it out as well.
If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
Even if you’re a casual reader of our blogs, you already know that EXAIR Application Engineers LOVE to preach efficiency in the use of compressed air…it’s our “bread and butter;” the very nature of our business. This year, we’re celebrating thirty-five years of leading the way in the development of efficient, safe, and quiet compressed air products. Our track record of success as a solutions provider across a diverse range of industrial and commercial applications is well documented in our blogs, as well as Knowledge Base and Case Study Libraries. We devote considerable resources (engineering, research & development, product testing, etc.) to making certain that EXAIR Intelligent Compressed Air Products cost less to operate, and perform better, than whatever you’re using right now.
Strange as it may seem, though, sometimes our products are EXTREMELY popular in cases where they INCREASE a facility’s consumption of compressed air…by replacing something that DOESN’T use compressed air at all:
*I’ve written before about how our Large Maximum Cold Temperature Vortex Tubes have replaced liquid nitrogen rigs in freeze sealing operations. Now, a Vortex Tube directs a portion of its air supply to (usually) unusable hot exhaust, in order to generate the usable flow of cold air. When compared to the costs of liquid nitrogen and the resources involved to get it where it needs to be, though, the cost of the compressed air needed to operate the Vortex Tube is indeed the practical solution.
*Line Vacs are probably THE prime example of the value of using compressed air where it wasn’t used before…replacing a “bucket and ladder” operation:
*Then there are the situations that just come down to time. In large spaces, our Super Blast Safety Air Guns can be used to “sweep” the floor in a fraction of the time it takes an operator with a push broom.
To make a long story just a little bit longer…if you’re using compressed air, you can use it better with EXAIR’s engineered compressed air products. And there are plenty of practical applications where you’re not using compressed air right now too. If you’d like to find out more about either one, give me a call.
Recently, I was working with a customer looking for a Premium Reversible Drum Vac and wanted it shipped to the Northwest Territories of Canada – which we could do! It got me to thinking, what are the farthest US state and territory locations EXAIR has shipped to in the North, South, West and East directions. I ‘scoured’ the records and came up with these.
Furthest North- We have shipped to Prudhoe Bay, Alaska. Most recently, believe it or not, we shipped a NEMA 4X Cabinet Cooler to an Oil and Natural Gas Exploration Company. Goes to show that even the coldest environments still have the need to provide cool, clean, dry air to cool and protect electronics in electrical enclosures.
Furthest South – We have shipped to the US Territory of Puerto Rico, city of Santa Isabel. An Aerospace company needed a strong, laminar blast of air and utilized a 6″ Stainless Steel Air Knife. An Air Knife offers a quiet, efficient way to clean, dry or cool parts, webs, or conveyors.
Furthest West- We have shipped to the US Territory of Guam. The local University ordered a model 1111-4 Super Air Nozzle Cluster, for a good strong blast of air flow for a cleaning operation. The model 1111-4 delivers 3.2 lbs of force, at just 82 dBA of sound. A safe and efficient nozzle for blowoff operations.
Furthest East- We have shipped to Eastport, Maine. The customer in Eastport ordered a Line Vac and a section of Conveyance Hose. The Line Vac is a great tool for conveying large volumes of material over long distances, through a standard hose or tube. The compact design features large throat diameters for maximum throughput capability.
It was interesting to look back and see all the places that EXAIR has shipped. We have customers from all over the globe. If you are outside the of 50 US States and Canada, we have a dedicated team of International Application Engineers that will work with you to select the best EXAIR product for your process and application, and direct you to your local International Distributor.
If you would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
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.