Tag: audit

How One Customer Improved Safety and Reduced Noise with a Simple Retrofit

Published on by Brian FarnoLeave a comment

I recently had the opportunity to help a customer facing some serious concerns about their compressed air usage. They had just completed a safety audit conducted by a third-party firm, and one of the main issues identified was the use of handheld blow guns throughout their production floor.

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

Even though the tools in question were commercially available and marketed as having “safety tips,” the auditors recorded noise levels exceeding 90 dBA—well above the acceptable threshold. The audit team explained that to maintain a safe work environment, noise levels needed to stay below 84 dBA, and the simplest way to get there was to address the blow guns being used.

That’s when the customer turned to us for help.

We discussed the application in detail, and it quickly became clear that EXAIR’s Model 1100 Super Air Nozzle would be a great fit. Not only does it significantly reduce noise levels—down to 74 dBA—but it also meets OSHA’s 30 PSI dead-end pressure requirement, ensuring operator safety in the event of a blocked nozzle.

This customer wasn’t focused on maximizing air output or performance—they simply wanted to make their environment safer for their team. What made this installation even better was the unexpected benefit: while addressing the safety concerns, it also reduced compressed air consumption. A win-win.

It’s always rewarding when we can help customers meet compliance goals and improve safety, but it’s even better when we can go beyond their expectations and help them uncover savings they weren’t even looking for.

Free testing. Verifiable data. EXAIR Efficiency Lab.

If you’re dealing with high noise levels or safety compliance issues around your compressed air applications, don’t hesitate to reach out. Our team is ready to help you find a solution that protects our people, meets regulations, and improves overall efficiency through the EXAIR Efficiency Lab.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR’s Efficiency Lab can Help With your Energy Audit, Quantify Savings and Provide an ROI

Published on by Brian FarnoLeave a comment

I recently received an inquiry from a customer to test their current air guns through our Efficiency Lab service. According to the operators, the handheld blow gun they were purchasing from a commercial retailer was too loud and complaints were rolling in.  They were also hoping to save some compressed air in the process as they were performing an energy audit at the same time.

Commercial Air Gun w/ Cross Cut Hole
Commercial Air Gun w/ Cross Cut Hole

Cross Cut Hole Nozzle
Cross Cut Hole Nozzle

The gun they sent in looked fairly similar to our Precision Safety Air Gun but it did not have an engineered nozzle on the tip of it.   Instead, it was simply a cross cut hole in a piece of material.   The air inlet to the gun was a 1/4″ NPT just like our Precision Safety Air Gun, the extension on the gun was slightly longer, the only significant variance I saw was the tip.

EXAIR Model 1410SS-CS
EXAIR Model 1410SS-CS

The Model 1110SS Nao Super Air Nozzle and Chip Shield
The Model 1110SS Nao Super Air Nozzle and Chip Shield

To try and get as much information as possible I measured the O.D. and I.D. of the extension, the hole size was approximately .140″.  I measured the extension on our Precision Safety Air Gun just to see what is different, it came in at the same size.  So, I flow tested the competitive blow gun with their tip on it and came up with air consumption of 12.69 SCFM, noise level of 92 dBA at 3′ away, and a blowing force of 11.5 oz at 80 psig.   I then measured the same attributes of EXAIR’s model 1410SS-CS Precision Safety Air Gun at 80 psig inlet pressure.  The model 1410SS-CS measured 8.3 SCFM, gave 8.1 ozs of working force, and only produced a 75 dBA sound level from 3′ away.

The sound level reduction was a total of 17 dBA which is below the OSHA standard for allowable noise level exposure, as well as reduced their air consumption by 4.39 SCFM.  That is almost a 35% reduction in their compressed air usage per gun replaced.  After seeing these levels of reduction the customer had more than enough information to provide management with in order to replace the blow guns not just for noise level reduction but also because it will reduce air use and save money. A clear supportive role in their energy audit.

If you would like to discuss how EXAIR can provide some free force, flow, and noise level testing for your facility, please contact an Application Engineer or check out the Efficiency Lab page on our site.

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