I received an email from an engineer that was looking at our Super Air Nozzles. They currently were using four blow-off lines that were made from 6mm ID copper tubes. (Reference picture) The system was designed to blow out holes after machining. The engineer was in charge of the task of optimizing 25 machining stations similar to this one. He was familiar with EXAIR products from his previous employment, and he recognized the waste of compressed air by using open pipe. He purchased four Nano Super Air Nozzle, model 1110SS, for a trial. He was impressed with the performance, the low sound level, and the engineered design in safety. But, for upper management in his company, he had to show a cost savings in order to change all the stations in the facility. He asked me to help him in calculating the compressed air savings.
He gave me some additional details about their application. He was using the compressed air about 30% of the time throughout an 8 hour day at a pressure of 80 PISG. He wanted to present the savings per day, week, and year as well as the payback period in his evaluation. I have performed many of these calculations for other customers and was happy to help. It is sometimes easier to speak in terms of savings, as everyone can relate to money, especially management. (The numbers below can be adjusted to match your application and blow-off devices).
Cost of compressed air: $0.25/1000 cubic feet of air (this is based on $0.08/Kwh of electrical cost)
Flow: 1110SS Nano Super Air Nozzle – 8.3 SCFM at 80 PSIG
Flow: 6mm ID copper tube – 42 SCFM at 80 PSIG
The difference in compressed air flows from a 6mm tube to the Nano Super Air Nozzle is (42 SCFM – 8.3 SCFM) = 33.7 SCFM. At a 30% duty cycle, we get 33.7 SCFM * 0.3 = 10.2 SCFM (cubic feet/minute) of additional compressed air being used.
Per day, the additional amount of compressed air wasted is:
From these values, the payback for a model 1110SS Super Air Nozzle is just under 38 days. Because the EXAIR Super Air Nozzles are so efficient, some utility companies will offer a rebate program to use them. This will improve your ROI even more. (We can check to see if your local electric company participates in these programs). Just think, the remaining life of the Super Air Nozzle will be using less compressed air and saving much money for the company.
The calculations above are only for one nozzle. As discussed above with the engineer, they had 4 tubes/station and 25 stations in their plant. So, if you multiply each figure by 100, you can see the large amount of money that can be saved. The engineer presented these figures to upper management, and it was an easy decision to replace all the copper tubes with EXAIR nozzles.
Don’t be fooled by the initial cost of a tube, pipe, drilled holes, or a substandard nozzle. You can see by the facts above, if you use any additional compressed air in your blow-off application, it will cost you a lot of money in the long run. If you need any help in calculating how much money EXAIR products can save you, you can use our Air Savings Calculator from our website, or you contact an Application Engineer at EXAIR. We will be happy to help you.
Return on Investment (ROI) is a measure of the gain (preferably) or loss generated relative to the amount of money that was invested. ROI is typically expressed as a percentage and is generally used for personal financial decisions, examining the profitability of a company, or comparing different investments. It can also be used to evaluate a project or process improvement to decide whether spending money on a project makes sense. The formula is shown below-
A negative ROI says the project would result in an overall loss of money
An ROI at zero is neither a loss or gain scenario
A positive ROI is a beneficial result, and the larger the value the greater the gain
Gain from investment could include many factors, such as energy savings, reduced scrap savings, cost per part due to increased throughput savings, and many more. It is important to analyze the full impact and to truly understand all of the savings that can be realized.
Cost of investment also could have many factors, including the capital cost, installation costs, downtime cost for installation, and others. The same care should be taken to fully capture the cost of the investment.
Example – installing a Super Air Nozzles (14 SCFM compressed air consumption) in place of 1/4″ open pipe (33 SCFM of air consumption consumption) . Using the Cost Savings Calculator on the EXAIR website, model 1100 nozzle will save $1,710 in energy costs. The model 1100 nozzle costs $37, assuming a $5 compression fitting and $50 in labor to install, the result is a Cost of Investment of $92.00. The ROI calculation for Year 1 is-
ROI = 1,759% – a very large and positive value. Payback time is only 13 working days.
Armed with the knowledge of a high ROI, it should be easier to get projects approved and funded. Not proceeding with the project costs more than implementing it.
If you have questions regarding ROI and need help in determining the gain and cost from invest values for a project that includes an 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.
Using compressed air in the plant is common for many types of processes. Typical uses are drying, cooling, cleaning and conveying. Compressed air does have a cost to consider, and there are many ways to keep the usage and the costs as low as possible. The first step is to use an EXAIR Intelligent Compressed Air Product, which has been engineered to provide the most performance while using the least amount of compressed air. The next step is to control the use of the air, to only have it on when needed.
EXAIR offers the EFC – Electronic Flow Control. It offers the most comprehensive method to maximize the efficiency of compressed air usage. It combines a photoelectric sensor with a timing control that operates a solenoid valve to turn on and off the air as required. With 8 different program types, an on/off mode that works with any process can be programmed ensuring that the minimum amount of compressed air is used. You can use the online EFC Savings Calculator to see how quickly the savings add up!
Another method would be to use a solenoid valve with some other method of control. Depending on the process, the solenoid could be energized via a machine control output, or as simple as an electrical push button station. EXAIR offers solenoid valves in a variety of flow rates (from 40 to 350 SCFM) and voltages (24 VDC, 120 VAC and 240 VAC) to match the air flow requirements of the products we provide, while integrating into the facility and available supply voltages.
For control of the Cabinet Cooler Systems, the ETC – Electronic Temperature Control, uses a thermocouple to measure cabinet temperature and cycle the system on and off to maintain a precise cabinet temperature, and provides a digital readout of the internal temperatures and on the fly adjustment. Also available is the Thermostat Control models, which utilize an adjustable bimetallic thermostat to control the solenoid valve, also cycling the unit on and off as needed to maintain a set cabinet temperature.
There are several manual methods that can be used to control the compressed air. A simple valve can be used to turn the air off when not needed, whether at the end of the work day, at break time, or whenever the air isn’t required. We offer several options, from a foot controlled valve, to a magnetic base with on/off valve, to a simple quarter turn ball valve.
To discuss your processes and how an EXAIR Intelligent Compressed Air Product can control the air supply and save you money, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.
If you have ever looked through our catalog, website, blog, twitter feeds, or even our Facebook page, you will see that we can almost always put a dollar amount behind the amount of compressed air you saved by installing EXAIR’s Intelligent Compressed Air Products. No matter which platform we use to deliver the message, we use the same value for the cost of compressed air which is $.25 per 1,000 Standard Cubic Feet of compressed air. This value is derived from average commercial and industrial energy costs nationwide, if you are on either coast this value may increase slightly. On the positive side, if your cost for compressed air is a bit more, installing an EXAIR product will increase your savings.
So where does this number come from? I can tell you this much, we didn’t let the marketing department or anyone in Accounting make it up. This is a number that the Engineering department has deemed feasible and is accurate.
To calculate the amount we first look to what the cost per kilowatt hour is you pay for energy. Then we will need to know what the compressor shaft horsepower of the compressor is, plus the run time percentage, the percentage at full-load, and the motor efficiency.
If you don’t have all of these values, no worries. We can get fairly close by using the industry accepted standard mentioned above, or use some other general standards if all you know is the cost of your electricity.
The way to calculate the cost of compressed air is not an intense mathematical equation like you might think. The best part is, you don’t even have to worry about doing any of the math shown below because you can contact us and we can work through it for you.
If you prefer to have us compare your current compressed air blow off or application method to one of our engineered products, we can do that AND provide you a report which includes side by side performance comparisons (volume of flow, noise, force) and dollar savings. This refers to our free Efficiency Lab service.
If you already know how much air you are using, you can use the Air Savings Calculators (USD or Euro) within our website’s knowledge base. Just plug in the numbers (EXAIR product data is found on our website or just contact us) and receive air savings per minute, hour, day and year. We also present a simple ROI payback time in days.
Now, back to the math behind our calculation. Cost ($) =
(bhp) x (0.746) x (#of operating hours) x ($/kWh) x (% time) x ( % full load bhp)
bhp — Compressor shaft horsepower (generally higher than motor nameplate Hp) 0.746 – conversion between hp and KW Percent Time — percentage of time running at this operating level Percent full-load bhp — bhp as percentage of full load bhp at this operating level Motor Efficiency — motor efficiency at this operating level
For an average facility here in the Midwest $0.25/1,000 SCF of compressed air is accurate. If you would like to attempt the calculation and or share with us your findings, please reach out to us. If you need help, we are happy to assist.