EXAIR Application Details Guide

The EXAIR website is valuable resource for reviewing and getting information about the many Intelligent Compressed Air® Products that we manufacture and sell.  It is a good place to learn more about the products, how they work, calculate air savings, see the many styles and materials of construction and much, much more.

If you have a specific application and would like us to review the process parameters and get our recommendation as to the best way to solve the issue, you can utilize the Application Assistance Worksheet located on the Left Menu Bar on many of the Product Pages.

Capture

Clicking on the Application Assistance Worksheet will provide you with a couple of ways to access the form.  Choosing one of the options will present you with the form below.

ApplicationDetailsGuide

This form has sections regarding Process Description, Part Specifications, Product Movement, and Other for general information.  By filling out this form with as much detail possible, and then online submitting or emailing to applications@exair.com, one of our Application Engineers will review and be in contact with you to further discuss in preparation for presenting a solution for you.

Or – to discuss your processes and how an EXAIR Intelligent Compressed Air® Product can provide a beneficial service, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Another Piece To The Puzzle

With having three young children, puzzles are a very popular item in my house.   Whether it is a wooden puzzle where you are matching different color fishes into their corresponding recess on a board, or maybe a classic Rubik’s Cube that I will get half way through solving when one of my daughters wants to help mess it up.  (Which I absolutely love to help them do because I watch their face as they turn each side and it is simply a look of pure joy and amazement. No matter the case, the puzzles always get solved and then they are guaranteed to be done again.

Cabinet Cooler

Here at EXAIR, I look at nearly every application I come across as a puzzle.   Sometimes, we have the exact piece that has a precise place and fit.  This could be a Cabinet Cooler System to cool and overheating electrical panel.  More often than not, it’s not that easy.  We spend a good margin of our time creating a picture in our head of what the customer’s application is and we try to find that missing piece to the puzzle that will complete their needs.

This is one of the great things about the Application Engineering Department here at EXAIR, each one of us has a very diverse professional background and very different life experiences which permits us to cover just about any scenario you can throw at us.  If one of us hasn’t experienced it, there is a good chance we have someone outside of our department who has and we will bring them in on the problem solving.  It’s not too uncommon for certain applications to even make it into the eyes and ears of the President of EXAIR due to his extensive background with many industries.

The point is, if we can’t figure it out, we know who to ask, if they don’t know, we’re going to try our hardest to get you the right product to fit your needs and exceed your expectations the first time. If not, we honor a 30 day guarantee on stock products and will take the product back so you know that we have exhausted all options.   We’ve even been known to call former customers back when we come out with new products that will fit their needs we weren’t able to meet.

30 Day Guarantee
30 Day Guarantee

If you think you have a hard to solve compressed air application, contact us.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Life Hacking = Better Easier Life. So What Happens When You Hack Compressed Air?

The birth of the internet and personal computer brought to light a new form of hacking.  For many years now hacking has been considered a negative action, even criminal.  However, within the past several years the term lifehacking has come to mean a process of bettering your life through tips and tricks.  There are entire blogs and TED talks about life hacking, so that has gotten me thinking of how can EXAIR hack your compressed air system and turn it into a life hack?

All of our products are designed and engineered to make your life easier and better.  The best product I can think of to demonstrate this is our Super Air Knife With Plumbing Kit Installed.  This is an option for any of our Super Air Knives which are longer than 24″ that makes installation even easier on your end.  The plumbing kit has already connected air to each port on the Super Air Knife so all you have to do is plumb air to a single port at the end of the kit assembly.  See the picture below for a better idea.

Alumina dust 3 PKI

Another item that has helped many customers is our Chip Trapper System.   This is essentially a modified or hacked Reversible Drum Vac System which  adds the benefit of filtering the liquid you are sucking up to a 5 micron level.  (Other filter levels/sizes available.) This means you can make your cutting fluid last longer and cut that rancid coolant smell in your machine shop down because the bacteria in the coolant doesn’t have any solids to live upon.  This also means that you won’t be giving your coolant reclamation company any of your valuable solids so you keep more of your scrap profits.

So if you are looking for a way to make your life easier while you are working with compressed air, let us know, we’ll see how you can hack your compressed air applications.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Who You Gonna Call?

This week the world lost a great writer, actor, and comedian with the death of Harold Ramis. Ramis is famous on screen for playing Dr. Egon Spengler in the movie Ghostbusters. What he wrote surprises me even more. Looking through Ramis’s IMDB page, I find most movies that I loved as a kid or that my dad quoted to me on a regular basis had Ramis’s name as a writer. Just to recap for the uninitiated in the cult of Ramis, his writing credits include Animal House, Meatballs, Caddyshack, Stripes, Ghostbusters, Groundhog Day, and Analyze This. He also directed Caddyshack, National Lampoon’s Vacation, Multipilicity, Bedazzled, and Year One. He also has a severely overlooked scene in Knocked Up as the grandfather to be. Talking to my wife I discovered, that she may or may not have seen the entire Ghostbusters movie, so now we have our big weekend plans.  I tried to get her to watch already, but she seemed distracted. I will just try again this weekend.  I’m thinking a Ramis marathon is in order.  I’m thinking CaddyShack, Ghostbusters, Ghostbuster 2 and Groundhog Day.

ghostbusters

The closest thing to a family rated movie in the list is Ghostbusters, though as I was reminded by my colleagues there are some off color jokes. Maybe it is best to find it on TV, if you are going to watch with the kids. One of my favorite scenes is when the hotel manager, played by Michael Ensign, has to call the Ghostbusters as a last resort. The hotel is a very ritzy joint, where problems like physics, logistics and ghosts should obviously be no problem for the immense amount of money it costs to rent out their grand ballroom. It is not in the movie, but you could imagine the Michael Ensign character has already called an exterminator, a priest, and the police.  None of these people have had any luck removing the green slimy ghost from the hotel. Therefore, on the night of a great party for an important guest, he has to stoop to calling the Ghostbusters.  Hilarity ensues.

After this scene, we are reintroduced to the great Ray Parker Jr.’s great Ghostbusters theme song known in my house as ““Who You Gonna Call?” Well if you have an industrial compressed air problem or general manufacturing question, EXAIR is a great place to start. With over 100 years of industrial experience available and 45 years with the company, the Application Engineers who answer technical questions here at EXAIR should be able to help you. Even if we don’t have the product/process for you, we have a wealth of contacts that provide cooling, blow off, coating, cleaning and painting options to help you solve your problem. Just don’t call us about ghost, we’ve got nothin’. We could help you create a ghost effect for your April Fools joke.  Air Amplifiers and some neon streamers under a black light can scare anyone, but I will use that in some other blog.

Harold R

Bye Mr. Ramis you will be missed!

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Stainless Steel Line Vac Conveys Egg Shells from Harvester to Waste Bin

IMG_0787

Our customer has a process where they de-cap eggs which are used in a variety of processes ranging from large scale bakery uses to medical uses for developing vaccines. The problem is they are left with a reasonable amount of egg shell waste that needs to be cleaned up after each cycle in the de-capping process. The previous method relied simply on friction and gravity to get the egg shell to go into the direction the customer wanted.

The problem with this method is that reliability was quite low. Egg shell would remain inside the egg, inside the tooling and pretty much everywhere around the de-capping process. The customer wanted to clean things up in the process a bit and increase the reliability that the shells go where they want them to which is a waste container about 5 meters away from the de-capper. The rate of shell flow was about 20 kilos per hour.

The customer made a search on the Internet for Air Vacuum conveyors and found EXAIR Corporation. After a short discussion to find out the specifics concerning rate of flow, distance, density of the product and available air pressure, we were able to make a suitable recommendation.

We ended up recommending EXAIR Model 6963 (1-1/2” Stainless Steel Line Vac kit). Having the full kit available allows the customer to install the Line Vac using included bracket for mounting as well as the air filter/separator and compressed air regulator with gauge to allow for accurate tuning of the air pressure to get just the right amount of suction from the Line Vac unit.

The customer purchased the recommended kit and installed on their machine. They have claimed the reliability has gotten to the point where the problem has nearly gone away. They still had some issues with the blades used, which they intend to sort out as a next step in their process of continuous improvement.

Neal Raker
Application Engineer
nealraker@exair.com

Exterior Surface Cleaning with Super Air Knife

With the variety of technological tools at our resources nowadays, it’s common to receive application photos from the field.  It’s also becoming increasingly popular to receive videos, which are even better because they show the process in action.

The video above, for example, was taken on a smartphone and sent over in regards to a problem keeping a drum clean.  Originally, a cotton pad was used to keep the exterior of the drum clean and debris free.  The cotton pad was directly in contact with the drum and over a relatively short period of time, the pad would wear away.

The solution for this application was the Super Air Knife.  Keeping a very similar mounting setup, and aiming the output airflow 45° opposite to the direction of drum rotation, the Super Air Knife can be positioned to keep the drum clean.  And, this process now requires little to no maintenance.

If you have a similar application, or a not so similar one but want to send in a photo or video for advice, my email contact is below.

Lee Evans
Application Engineer
leeevans@exair.com
@EXAIR_LE

Short fast week. No shortage of success.

That’s right everyone, it’s Friday.   I’m blogging again which means everything went according to plan on Monday and Tuesday at Mid Ohio.  Myself and everyone I went with all stayed shiny side up so we consider it a complete success.  Even though it’s been a short week for me here at EXAIR there hasn’t been a lack of applications coming across my desk.  As Lee mentioned in his blog yesterday a good number of them are Cabinet Cooler inquiries seeing as how much of the US is well into the Summer temps now.  One of the applications that came across stood out though.

There was a customer who started out the conversation with, “I’m not a compressed air person.  I normally work with electricity.”  He was given the task of trying to figure out how to cool down a part as it exits a drying oven.  The parts were fairly flat and being conveyed on an overhead conveyor system.  They slowing down production of the parts because he couldn’t package the parts after they exited the drying oven because the heat from the part was not only too much for the operators to handle but it was also too hot for the packaging.  When the part would go in too hot the packaging would slightly mar the surface finish of the coated part.  This meant the customer was placing parts on drying racks and letting them cool which slows down the production line.

The customer initially wanted to cool down the part using a Vortex Tube to do so.   After a brief discussion I found out that the ambient environment of the cooling area was considerably cooler than the part and the parts were around 11″ long.  This means by using a 12″ Super Air Knife we can entrain a large volume of free ambient air and move the air over the surface of the part to strip the heat away from the part.  This will get the parts down to near ambient conditions so the operators can place them straight into their packaging instead of holding up the line or placing them on a cooling rack.

The customer initially contacted us looking for something that puts out cold air, he hadn’t thought about just using a large volume of cool, free ambient air to move over the part and get the same performance.   After a little talking he decided to test out two 12″ Super Air Knives.  He knows if they don’t work as predicted then they can simply let us know and send them back within 30 days. A similar application is shown below.

The customer received the units yesterday and this morning I had a message from the customer saying that the knives are working wonderfully and he is not using any cooling racks, they were even able to speed up the production line.

This made my week go amazing; it started out with two days of a beautiful race track, going faster than I ever have and stepping up to the next class of racing, then finishing it out with a success story from a customer who can now relax on the weekend.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF